Production of shredded or flaked whole grain-containing composite food products

ABSTRACT

Shredded or flaked whole grain-containing composite food products, such as ready-to-eat cereals, and sweet and savory snacks, are continuously produced by pelletizing cooked, tempered, whole cereal grain particles in the presence of vegetables, fruit, or dairy cheese. In another aspect, an enrobing coating containing chocolate is applied to a baked shredded laminate product of the pelletization, wherein the shredded product may further optionally include fruit added and present during pelletization.

This patent application claims priority from and is a continuation ofU.S. application Ser. No. 11/382,306, now U.S. Pat. No. 8,367,142,entitled “Production of Whole Grain Shredded Products”, which was filedon May 9, 2006, which is a continuation-in-part of U.S. application Ser.No. 11/265,960, now U.S. Pat. No. 7,939,122, entitled “Production ofWhole Grain Shredded Products”, which was filed on Nov. 3, 2005, whichis a continuation-in-part of U.S. application Ser. No. 11/119,077, nowU.S. Pat. No. 7,964,233, entitled “Production of Whole Grain ShreddedProducts”, which was filed on Apr. 29, 2005, and each of which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to production of shredded or flakedcomposite food products, such as snacks and ready-to-eat cereals, fromcombinations of whole cereal grains and other food components.

BACKGROUND OF THE INVENTION

Whole cereal grains are nutritious and provide high dietary fibercontent. Shredded products have been historically made with whole grainwheat. Generally, in the production of shredded wheat ready-to-eatcereal biscuits and shredded wheat wafers from whole grains, a pluralityof shredded layers are laminated upon one other, and the laminate iscut, dockered, and baked to provide products having a distinctly visibleshred pattern on their opposing major surfaces. The shreds providevisual attractiveness and a unique, crispy texture and connote ahealthy, hearty, natural product. Also, the shreds provide increasedsurface area and deliver a robust flavor.

To prepare wheat for shredding, whole wheat berries are generally cookedand then tempered, using prolonged tempering times. Wheat is generallyeasy to shred over long periods after the cooking and tempering, forexample up to about 24 hours after tempering. Whole wheat is unique inthat it contains gluten which helps to retain water and to providecohesiveness and elasticity during machining even after prolongedperiods after tempering. However, the same is not true for other grainsbecause of their lack of gluten and their unique chemical compositionand changes that happen to the grains after cooking and tempering.

Starch-based compositions which have little or no gluten, when mixedwith water, tend not to form dough that is cohesive at room temperatureand continuously machinable or sheetable. Machinability of dough madefrom ingredients having little or no gluten may be improved by formingdough under elevated temperature conditions, such as by steaming theingredients, as disclosed in U.S. Pat. Nos. 4,873,093 and 4,834,996 toFazzolare et al. However, in the production of shredded products fromcooked, tempered, non-glutenous whole grains such as corn, oats, rye,and barley, shreddability into long continuous shreds tends to decreaseas tempering times increase or as the time between tempering andshredding increases. For example, cooked corn has a tendency to becomehard and rubbery during the cooling and tempering process due, it isbelieved, to starch retrogradation. Also, storing of tempered corn insurge bins to accommodate mass production processes tends to increasestarch retrogradation and hardness. The cooked, tempered cereal grainswhich become hardened or rubbery, tend to fracture during shredding ordo not conform to shredding roll grooves for producing continuous,well-defined shredded net-like sheets.

In conventional processes for producing shredded cereals, the grain iscooked and then permitted to temper to increase shred strength.Tempering of the cooked grains prior to shredding has generally beenconsidered necessary for obtaining strong, continuous shreds. In U.S.Pat. No. 548,086 and U.S. Pat. No. 1,159,045, cooked wheat or similargrains are subjected to tempering times of over 12 hours beforeshredding. As described in U.S. Pat. No. 4,179,527, in the manufactureof a whole wheat food product such as shredded wheat, whole wheat iscooked sufficiently to gelatinize the starch. Gelatinization is afunction of water penetration into the whole berry, temperature, andtime, for a given type of grain. According to U.S. Pat. No. 4,179,527,the gelatinization of wheat starch involves a destruction of bonds inthe crystalline regions of starch granules. Retrogradation is the returnof the starch molecules to a crystalline structure, which is differentfrom the original crystalline structures, upon cooling. Temperingpermits the gelatinized wheat starch to slowly cool and permits watermigration through the wheat particles to achieve a uniform waterdistribution within the particles. Retrogradation occurs duringtempering. According to U.S. Pat. No. 4,179,527, if shredding isattempted shortly after cooking, the insufficient degree ofretrogradation or tempering results in at best, short noncontinuousstrands and/or strands which are tough, curly, or suffer from otherphysical or textural disadvantage. In U.S. Pat. No. 4,179,527, the timerequired for the tempering of cooked whole wheat is substantiallyreduced by chilling the wheat at a temperature of from 1° C. to about12° C.

It is believed that for wheat, the tempering permits distribution ofwater and facilitates development of the gluten into a network whichprovides cohesiveness for shredding. It is also believed that theretrogradation of wheat starch during tempering or after tempering isslow so as not to impede shredding or it forms a crystalline structurewhich permits shredding in the presence of gluten. Tempering ofnon-glutenous grains, such as corn, oats, rye, and barley also help todistribute water throughout the starch granules. It is believed thatrelease of some soluble starch during cooking and distribution of thestarch and water during tempering helps to provide cohesiveness.However, the amount released may be insufficient for continuousshreddability or starch retrogradation may be too rapid and may providea crystalline structure which impedes shreddability into long continuousshreds.

Numerous other processes for producing shredded cereal products withreduced tempering times or without any apparent tempering is also known.Shredded cereal products, whether tempering is used or not, have alsobeen produced by shredding the cereal in a form other than its cookedberry form.

International Patent Publication Nos. WO 03/034838 A1 and WO 03/024242A1, and U.S. Patent Application Publication No. US 2004/0166201 A1disclose the addition of an enzyme to starch-based raw materials toaccelerate the retrogradation of starch and thus allow a shortening ofthe tempering step in the production of snack pellets and in theproduction of shredded cereals.

U.S. Pat. No. 6,303,177 and European Patent Application Publication No.EP 1,132,010 A1 disclose the production of a soy containing breakfastcereal by extrusion cooking a composition containing a soy material anda cereal grain to obtain a substantially gelatinized dough. Aconventional pelletizer may be used to form dough beads from the cookeddough as it is extruded from the forming extruder. The pelletizer bladescut the dough extrudate rope into beads or pellets for furtherprocessing into flakes or shredded cereal. The dough beads may be driedto a moisture content of less than 18% and then the dried beads may betempered for about 4 hours to about 10 hours before shredding.

U.S. Pat. No. 5,368,870 discloses fortifying a ready-to-eat cereal withbeta carotene by adding to cooked tempered cereal grains prior to pieceforming. Tempering times may range from approximately 2 hours toapproximately 36 hours. The cooked cereals pieces may comprise cookedgrains or fragments such as whole wheat berries or grits, corn cones,oat flakes, and the like. After fortification, the cooked temperedcereal pieces may be formed into pellets for flaking or may be shred inshredding rolls.

U.S. Pat. No. 5,182,127 and International Patent Publication No. WO93/05665 disclose tempering of cooked cereal pellets or pieces forready-to-eat cereals or cereal based snack half products by exposing thepellets or pieces to a high intensity microwave field for a brief timesufficient to improve moisture distribution therein but without causingthe pellets or pieces to puff. The microwave tempered pellets or piecesmay be flaked or shredded.

U.S. Pat. No. 4,528,202 discloses the production of the ready-to-eatshredded potato products by combining at least one potato starch sourcewith water under low temperature and low shear mixing conditions so asto avoid overgelatinization of the potato starch and to form individualdiscrete dough pieces or particles, tempering the dough pieces for atleast about two hours to distribute the water substantially uniformlythroughout the dough pieces, shredding the tempered dough pieces, andcooking the shredded dough.

Processes where tempering is not specifically mentioned or is indicatedas being optional in the production of cereals from wheat or othergrains, are disclosed in U.S. Pat. Nos. 1,189,130, 2,008,024, 1,946,803,502,378, 897,181, 3,062,657, 3,462,277, 3,732,109 and Canadian PatentNo. 674,046.

In U.S. Pat. No. 1,189,130, thoroughly moistened bran, such as wheatbran, is mixed with up to 50% of whole wheat or other gelatinous cerealflour or starch-bearing material, and is cooked in pans in a steamretort. The cooked product is dried to a lumpy condition, the lumps arepressed through a vial mesh and the resulting rice sized lumps are thenfed through shredding mills.

U.S. Pat. No. 2,008,024, a cereal biscuit is prepared by steaming orboiling wheat alone or with other forms of cereal or food material,surface drying the cooked product, and then converting it into a thinribbed sheet. The shredding rolls are spaced sufficiently apart so thata sheeted material with ribs is obtained instead of a shredded product.

In U.S. Pat. No. 1,946,803, rice, alone or in combination with bran, issteam cooked, dried and cooled to a rubbery consistency, ground andoptionally tempered to effect a uniform water distribution. This productis then passed between grooved rollers to form long flat ribbons. Theseribbons are dried to produce a brittle product which is broken and thenpuffed by toasting.

In U.S. Pat. No. 502,378, a cereal grain is prepared for shredding byboiling, steaming, steeping or soaking. Depending upon the spacingbetween the rollers, a product in the form of threads, lace, ribbons, orsheets, and the like, is obtained.

In U.S. Pat. No. 897,181, cereal grain or vegetable in whole form iswetted but not cooked and then passed repeatedly between grooved rollersand then baked. Boiling or steaming of the grain or vegetable, it isdisclosed, produces considerable change in its chemical quality and anumber of the nutritious soluble elements escapes to the water.

In the processes of U.S. Pat. Nos. 3,062,657, 3,462,277, and 3,732,109,and Canadian Patent No. 674,046, a shredded product is not produced bymeans of shredding rolls. In U.S. Pat. No. 3,062,657, flour and waterare mixed to form a dough in an extruder. The dough is cooked in theextruder and then tempered in the extruder at a lower temperature. Theextrudates are cut into pellets to simulate cooked and dried grains suchas corn grits, whole wheat berries, oat groats, rice and the like. Theextrudates, it is disclosed, have a moisture content ideal for flaking.It is generally on the order of 18 to 24% by weight, the moisture beinguniformly distributed throughout so that the necessity for tempering isentirely eliminated and the extrudate can be immediately transferred toa flaking operation. It is disclosed that it is preferable to furthercool the extrudate before it enters the flaking device to optimizeflaking properties.

In U.S. Pat. No. 3,462,277, a mixture of cereal flour or grits and wateris passed through an extruder to gelatinize the starch while the doughis cooked and transformed into a rubber-like mass. The moisture contentof the mixture is 13 to 35%. The continuous U-shaped extrudate ispinched off into segments by cutting rolls to form canoe-shaped cerealproducts. The separated canoe-shaped pieces are then dried to below 15%moisture.

U.S. Pat. No. 3,732,109, discloses the production of a ready-to-eat oatcereal biscuit by subjecting an oat flour-water mixture to a waterboiling temperature and superatmospheric pressure to gelatinize aportion of the starch in the oat flour. The mixture then passes throughan orifice and the extruded product is cut into small pieces. Theflake-shaped pieces which are formed are dried to moisture content offrom about 2% to about 6% by weight water. The dried flakes are thensubdivided, admixed with a syrup, and compacted into the form of abiscuit. The formed biscuits are then dried to a moisture content offrom about 4 to 5% by weight.

In Canadian Patent No. 674,046, a shredded dry oat cereal product isproduced without the use of shredding rolls. Dough is cooked in a screwextruder, extruded through orifices to form a strand bundle, and thestrand bundle is cut into pieces by a cutting device which may be a pairof rolls.

Processes for the production of shredded cereals from cereal grainswherein considerable tempering is used, as in the conventional processfor the production of shredded wheat, are disclosed in U.S. Pat. Nos.1,159,045, 1,170,162, 1,197,297, and U.S. Pat. No. 4,004,035. In U.S.Pat. Nos. 1,159,045, 1,170,162 and 1,197,297, the whole berry ispulverized so as to permit flavoring ingredients to be incorporated inthe final product. A dough is formed from flour, flavoring, and water.The dough is then cooked, rolled into slabs and then atmosphericallydried for a period of 24 to 40 hours. The dried product is toasted,broken into pea size pieces, dried and then shredded. In U.S. Pat. No.4,004,035, shredded biscuits are formed by depositing a layer ofshredded cereal in zig zag configuration on a moving belt to facilitatesevering the material. In addition to whole wheat, other foods capableof being shredded, such as other cooked cereal, wheat germ, defattedsoy, other vegetable protein, fruits, vegetable slurries and mixturesthereof may be employed in producing the biscuits. The food is softenedby cooking and tempering prior to shredding.

In the production of shredded cereals by means of shredding rolls,obtaining the cooked cereal in a form which will produce continuousshreds is only one of several problems which are encountered.

Cooking to eliminate white centers in grains is taught in U.S. Pat. No.2,421,216 and U.S. Pat. No. 4,734,294. In U.S. Pat. No. 2,421,216,particles of cereal grains such as corn, rye, wheat, bran, rice, or oatgroats are composited with particles of de-fatted soya beans in the formof grits, flakes, or meal to enhance the protein content of the cerealby use of a two-stage pressure cooking step: The total cooking period towhich the cereal component is subjected to should, according to U.S.Pat. No. 2,421,216, be such that the starches are hydrolyzed and highlydextrinized and the particles superficially. gelatinized with no freestarch or white center. The cereal particles, it is taught, should alsohave a light adhesive action of the intermediately added soya beanparticles. The mixed mass of cereal and soy which is removed from thecooker, is dried, then tempered for about 15 to 30 minutes beforeshredding in a shredding mill wherein the particles of soya becomesubstantially uniformly spread out over and mixed with the cerealparticles and adhered thereto by pressure through the shredding rolls.

U.S. Pat. No. 4,734,294 discloses a process for the production ofshredded oat food products, such as ready-to-eat breakfast cerealshaving the shredded appearance and texture of shredded whole wheat.White streaks or spots in the final product, which result from uncookedgrain or overcooked grain, are eliminated by pressure cooking the oatsin at least two stages, the amount of water used in the first pressurecooking stage being limited to partially gelatinize the starch withoutsubstantial extraction of water soluble starches and gums to the surfaceof the oat particles. The amount of water used in the remaining pressurecooking stage or stages is sufficient to eliminate at leastsubstantially all of the white portions in the oat particles and toprovide water content in the oat particles which is sufficiently high toenable continuous shredding on shredding rollers. Additionally, theamount of water in each of the remaining stages is limited to avoidsubstantial extraction of the gums and water soluble starches to thesurface of the partially cooked oat particle.

In U.S. Pat. No. 3,512,990 a dough, made from farinaceous materials suchas wheat, corn, oats, rice, potatoes, or legumes, is optionallypartially or completely cooked with added moisture, to an approximatemoisture content of about 30%. After this cooking step, the mixture isrendered homogeneous by passing it through an extruder or a hammer mill,such as Fitzmill. The milled or extruded product is dried to anapproximate moisture content of 22 to 24%. The dried dough is thencompacted between two rolls to provide a shredding effect and produce asheet of dough having diamond-like regularly spaced perforations. Thesheet of dough is then severed into strips, folded to form smallbiscuits which are closed on three sides and then deep fried.

In U.S. Pat. Nos. 987,088, 1,019,831, and U.S. Pat. No. 1,021,473, cornor another grain is ground and immersed in an amount of water which islimited to that which will be taken up by the grain during cooking. Thepurpose of this is to preserve in the cooked article the aroma and otherproperties of the grain which might otherwise be carried off ordissipated by the evolution of steam or vapor. In these processes, thecooked dough is extruded through a perforated plate to obtain filaments.

In U.S. Pat. No. 4,310,560 particulate edible materials, including atleast one material which acquires surface stickiness when moistened anda chemical leavening system are contacted with a spray of water andformed into pellets on a pelletizing disk. The edible material mayinclude starches, such as those derived from wheat, corn, rice,potatoes, tapioca, and the like, including pregelatinized starches. Thepellets are heated to a temperature sufficient to effect reaction of theleavening system to release carbon dioxide to provide the pellets with aporous cellular structure.

SUMMARY OF THE INVENTION

The present invention relates to production of whole grain-containingcomposite food products, such as and thin crispy chip-like snacks,ready-to-eat cereals, and enrobed food products, in shredded or flakedform from whole grains or multi-whole grain mixtures.

A method is provided in one embodiment for improving the shreddabilityor flakability of retrograded, whole cereal grain particles in producinga shredded or flaked composite food product, in which the methodcomprises pelletizing cooked and tempered, whole cereal grain particlesthat have undergone retrogradation to a hard, fracturable texture, inthe presence of a food component selected from the group consisting ofvegetables, fruits, and dairy cheese, to obtain whole-grain containingcomposite food pellets having soft, pliable texture which are ready forshredding or flaking while avoiding stickiness problems. The compositefood pellets are shredded or flaked to provide shredded or flakedcomposite food pellets. In the instance of shreds, they additionally areformed into a shredded composite food laminate that is cut or otherwisedivided into discrete shredded composite food pieces. The flakedcomposite food pellets or shredded composite food pieces are baked toprovide a multi-flavored, nutritional shredded or flaked composite foodproduct.

Fruit or vegetables, when used as the food component, are combined i)with whole cereal grain particles before or during cooking thereof,and/or ii) with cooked and tempered whole grain particles beforecompleting the pelletizing step. Shearing and compaction of the combinedtempered, cooked grain particles and food component in the pelletizersoftens/plasticizes the matrix and generates enough of friction/heat tomake it pliable, and less hard and rubbery, and ready for flaking orshredding while avoiding stickiness problems. In view of the observedsoft, pliable characteristics of the resulting pellets, it is believedthat the retrogradation of starch is reversed during the pelletizationprocess. Moisture introduced via the fruit or vegetables, helpsgelatinize starches present in the whole grain. External moisturerequirements thus can be effectively reduced for the process operations.The pelletizing process also helps in eliminating problems otherwiseassociated with flaking or shredding grains such as oats or soy havingrelatively high fat content. The vegetables and fruits also impart aunique veggie or fruity taste, respectively, in the composite product,and serve as a natural source of vitamins and/or minerals, and othernutrients, to reduce macronutrient/micronutrient supplementationneeds/costs and provide more bioavailable forms of suchnaturally-delivered nutrients. The fruit, when used, may be selectedfrom figs (prunes), bananas, citrus fruits, cranberries, apples,strawberries, blueberries, raspberries, peaches, apricots, pears,pineapples, oranges, grapes, and the like and any combination thereof.The vegetables, when used, may be selected from the group consisting ofsweet potatoes, potatoes, cabbage, onions, carrots, spinach, broccoli,peas, beans, peppers, zucchini, okra, Brussels sprouts, cucumber,tomatoes, and the like and any combinations thereof. The fruit andvegetables may be used in the form of whole raw products thereof, wholefrozen products thereof, whole evaporated products thereof, wholepre-cooked products thereof, whole juices thereof, whole purees thereof,whole powders thereof, and any combination thereof. The whole grainparticles and fruit or vegetable food component may be combined in amixing ratio of about 20:80 to about 95:05, and particularly about 40:60to about 50:50, on a wt %:wt % basis, respectively, although the ratiomay vary depending on the relative moisture and solids contents of thetwo ingredients.

Alternatively the food component may comprise dairy cheese, which iscombined with cooked and tempered whole grain particles beforecompleting the pelletizing step of the above-indicated method to providea shredded or flaked composite product comprising grain material infusedwith cheese. In view of the soft, pliable attributes of thecheese-infused whole grain pellets, it also is believed that theretrogradation of starch is reversed during this pelletization process.This process also helps in eliminating or minimizing problems associatedwith flaking/shredding grains/seeds and cheese with high fat content.The composite products are a convenient form of delivery of both wholegrains and real cheese in a ready-to-eat shelf-stable product. They havedual nutritional benefits derived from whole grain and dairy productcontents. The dairy cheese particularly may have a moisture content ofno greater than about 20 wt %. The dairy cheese may comprise Parmesancheese, Romano cheese, Cheddar cheese, Swiss cheese, and the like andany combinations thereof. Optionally, the composite cheese-infused wholegrain shredded products also can be baked with additionally-addedcheese, which is incorporated in-between the shreds and/or added on topof the shreds before baking the product.

A method is provided in another embodiment for producing an enrobed,shredded composite food product, in which the method comprisespelletizing tempered, cooked, whole cereal grain particles which haveundergone retrogradation to a hard, fracturable texture, and optionallyin the presence of fruit, to obtain whole grain-containing pelletshaving a pliable texture, which pellets are shredded, formed into ashredded laminate that is cut or otherwise divided into discreteshredded food pieces, and then the discrete shredded food pieces arebaked to provide baked, shredded food substrates, which are enrobed witha chocolate-containing coating to provide multi-textured, multi-flavoredand nutritional enrobed, shredded composite food products. Thesecomposite products have wholesomeness of whole cereal grains combinedwith indulgence of chocolate. The texture of these composite products isunique in terms of bite and crunchiness.

The whole grains used in embodiments herein may comprise high-glutenwhole grains such as wheat and/or non-glutenous or low-gluten contentwhole grains, e.g., corn, barley, rice, rye, oats, triticale. In aparticular embodiment, the whole grains include non-glutenous orlow-gluten content whole grains. These whole grains may be used singlyor in multi-grain combinations thereof. Shredded and flaked compositeproducts of embodiments of the invention include, e.g., whole grainshredded snacks and ready-to-eat cereals, made from one or morenon-glutenous or low-gluten whole grains such as whole corn grains,oats, barley, rice, triticale, and rye. The method may also be employedwith whole wheat alone or in combination with other whole grains toprovide an enhanced crispy texture. In another embodiment of theinvention, a whole grain, shredded chip-like snack having asubstantially uniform shredded net like appearance and a crisp, shreddedtexture is obtained by substantially compressing a laminate of net-likesheets of the shredded composite pellets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart showing methodology of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a method for making shredded or flakedwhole grain-containing composite products, such as sweet and savorysnacks (e.g., chips, crackers, wafers, biscuits, enrobed shredded foods)and ready-to-eat cereals, and other food products. The products may bemade with 100% whole grains and are an excellent source of whole grainnutrition and fiber. Cooked whole grains, such as corn and othernon-gluten or low-gluten containing grains, when either processed aloneor in combination with food components such as fruit, vegetables ordairy cheese, have a tendency to become hard and rubbery during thecooling and tempering process due to starch retrogradation. Shearing andcompaction of whole grains in a pelletizer has been found tounexpectedly soften and plasticize the starch matrix and generatefriction and heat to make the whole grain particles pliable and readilyshreddable without stickiness problems in the shredding or flakingrolls. Moreover, this phenomenon is achieved even where disparate typesof food are co-present with the cooked, tempered whole grains in thepelletizer, such as fruit, vegetables or dairy cheese. It is believedthat in the process of the present invention, fracturing of at leastsubstantially gelatinized, tempered starch granules to release amyloseand amylopectin increases cohesiveness and softens whole cereal grainpieces for unexpectedly superior shreddability into continuous net-likesheets or superior flakability. As a consequence, starch retrogradation,it is believed, is reversed or amylose and amylopectin are released fromthe fractured starch granules during the pelletization process. The highshear, it is believed, substantially fractures retrograded starchgranules to increase cohesiveness for shreddability or flakability. As aresult, the pelletized whole grain, even if it incorporates fruit,vegetables or dairy cheese, is shreddable or flakable for a longerperiod of time after cooking. The difficulty with the shreddability orflakability of cooked and tempered grains, such as corn oats, barley,rice, triticale, and rye, either alone or when in combination withfruit, vegetables or dairy cheese, is overcome.

The process of the present invention provides versatility in terms oftempering times and post-tempering storage times for the production ofnutritious, good source of fiber content, single whole grain ormulti-whole grain shredded composite products. The pelletized cooked,tempered whole grains, and any incorporated fruit, vegetables or dairycheese, are continuously shreddable into continuous net-like sheets, orflakable, even after prolonged tempering times or after prolongedperiods in surge vessels after tempering during which substantial starchretrogradation may occur. The method of the present invention permitsthe use of fully cooked, tempered, but fracturable, hardened, rubberywhole cereal grain pieces, and composites of such grain pieces withfruit, vegetables or dairy cheese, in the continuous production ofshredded or flaked products while achieving well defined shreds and acrisp texture and good source of fiber content. Whole wheat shreddedcomposite products having an enhanced crispy texture can be producedusing short temper times with excellent shreddability or flakability inaccordance with the present invention.

Referring to FIG. 1, the flow chart shows a process scheme for makingshredded or flaked whole grain-containing composite food products inaccordance with various illustrative embodiments of the presentinvention. In the practice of particular embodiments herein, at leastone of Options 1-5 indicated in FIG. 1 will be applied. Additionalfeatures of this method and options thereof will become more apparentfrom the descriptions that follow.

In one embodiment, indicated as Option 1 of FIG. 1, a unique procedureis provided for making flaked/shredded composite food products usingvarious combinations of whole grains and whole fruits. The wholegrains/seeds that can be used to make flaked/shredded products includewheat, rye, rice, corn, oats, barley, soy, and so forth. They can beused in combination with whole fruits such as figs (prunes), bananas,citrus fruits, cranberries, apples, strawberries, blueberries,raspberries, peaches, apricots, pears, pineapples, oranges, grapes, andso forth and combinations thereof. The procedure involves cooking ofwhole grains along with whole fruit, whole fruit purees, 100% fruitjuices, whole frozen fruit, whole evaporated fruit, whole fruit powders,or combinations thereof, in a pressure cooker and then cooling andtempering the cooked material. Alternatively, the portions of the wholefruit may be selectively used, such as the flesh portions less seedsand/or skins. The cooked tempered whole grain and fruit material is fedinto a pelletizer/extruder to form pellets. The pellets are fed into theflaking or shredding rolls to make flakes or shredded layers. Shreddedproducts are formed, cut into desired shape, and then baked. Flakes arebaked directly. Alternatively, or in addition thereto,cooked/pasteurized whole fruit puree or 100% fruit juices or whole fruitpowders can be introduced directly into the pelletizer instead of addingthe fruit component in the pressure cooker. In the matrix or between theshreds or topically, vitamins, minerals, flavors/seasonings, and otheringredients can be incorporated to further enhance the nutrition, taste,and texture of the composite products. In one particular embodiment, themethod is used to make flaked/shredded products with 100% whole grainsand 100% real (raw natural) whole fruits. This method also can be usedto make cereals, baby foods, snack foods, and other products. In aparticular embodiment, the combination of whole grain and fruit are in amixing ratio of about 20:80 to about 95:05, and particularly about 40:60to about 50:50, on a wt %:wt % basis, respectively, although the ratiomay vary depending on the relative moisture and solids contents of thetwo ingredients. Optionally, the composite products also can haveadditionally-added fruit content incorporated after shredding/flakingand/or post baking.

The composited whole grain/fruit products are an excellent source ofwhole grains as well as good source of fiber. In addition the compositeproduct offers unique nutritional health benefits derived both fromwhole grains and whole fruits. The fruits also serve as a natural sourceof vitamins and/or minerals, and other nutrients, to reducemacronutrient/micronutrient supplementation needs/costs and provide morebioavailable form of such naturally-delivered nutrients. As indicated,the tempered material containing whole grains and fruits has a tendencyto become hard and rubbery during cooling due to starch retrogradationin grains. Shearing and compaction of the material in the pelletizersoftens/plasticizes the matrix and generates enough of friction/heat tomake it pliable and ready for flaking or shredding. In view of the soft,pliable pellet characteristics, the retrogradation of starch is thoughtto be reversed during the pelletization process in which cooked,tempered whole grains and fruits are used as co-feed materials. Thepelletizing process also helps in eliminating problems associated withflaking/shredding grains/seeds such as oats or soy with high fat andhigh protein content, and sugars in the fruits. Moisture in fruits isused as a substrate to gelatinize grains without added water and thusdeveloping unique fruity taste in the product. External moisturerequirements thus can be effectively reduced for the process operations.The fruits develop and impart a unique fruity taste in the compositeproduct. These composite products are a convenient form of delivery ofboth whole grains and whole fruits in a ready-to-eat shelf stableproduct. The whole grains and real fruits compliment each other innutrition, texture, and overall eating properties. Among the healthbenefits of the composite products; they are an excellent source ofwhole grains, good source of fiber, low or zero trans fatty acidsources, low saturated fat sources, low or zero cholesterol sources, andcan be made with low sodium content, and so forth.

Other advantages of this and other embodiments of the invention includethe versatility that the procedure offers in terms of usingwhole/pre-ground whole grains, method of cooking, tempering time,flakability/shreddability, and ability to incorporate other ingredientsto improve the functionality, nutrition, and overall acceptance of theproducts. In addition, by using of different cutter designs andflaking/shredding rolls patterns, the product geometry and pattern offlaked/shredded composite products of embodiments of this invention canbe changed to make it interesting and fun for consumers.

In another embodiment, indicated as Option 2 of FIG. 1, a uniqueprocedure is provided for making flaked/shredded products using variouscombinations of whole grains and real vegetables. The whole grains/seedsinclude those mentioned previously. They can be used in combination withvegetables such as onions, potatoes, sweet potatoes, cabbage, carrots,spinach, broccoli, peas, beans, peppers, zucchini, okra, Brusselssprouts, cucumber, tomatoes, and so forth and combinations thereof.Generally similar to the whole grain/fruit processing described above,this procedure involves cooking of whole grains and vegetables in apressure cooker and then cooling and tempering the cooked material,which is then fed into a pelletizer/extruder to form pellets. Thepellets also are fed into the flaking or shredding rolls to make flakesor shredded layers. Shredded layers are formed, cut into desired shape,and then baked. Flakes are baked directly. Alternatively, or in additionthereto, cooked and pasteurized vegetable purees/vegetablepowders/frozen vegetables/evaporated vegetables/100% vegetable juicescan be introduced directly into the pelletizer instead of adding in thepressure cooker. In the matrix or between the layers or topically,vitamins, minerals, herbs, caraway seeds, flavors/seasonings, and otheringredients can be incorporated to further enhance the nutrition, taste,and texture of the products. In one particular embodiment, thisinvention describes a unique procedure to make flaked/shredded productsusing 100% whole grains and 100% real (raw natural) vegetables.Alternatively, the portions of the whole vegetables may be selectivelyused, such as the flesh portions less seeds and/or skins. In aparticular embodiment, the combination of whole grain and vegetables arein a mixing ratio of about 20:80 to about 95:05, and particularly about40:60 to about 50:50, on a wt %:wt % basis, respectively, although theratio may vary depending on the relative moisture and solids contents ofthe two ingredients.

The composited whole grain/vegetable products are an excellent source ofwhole grains as well as good source of fiber. In addition the productoffers unique nutritional health benefits derived both from whole grainsand real vegetables. As indicated, the tempered material containingwhole grains and vegetables has a tendency to become hard and rubberyduring cooling due to starch retrogradation in grains. Shearing andcompaction of the material in the pelletizer softens/plasticizes thematrix and generates enough of friction/heat to make it pliable andready for flaking or shredding. In view of the soft, pliable pelletcharacteristics, it is believed that the retrogradation of starch isreversed during the pelletization process in which cooked, temperedwhole grains and vegetables are used as co-feed materials. Thepelletizing process also helps in eliminating problems otherwiseassociated with flaking/shredding grains/seeds such as oats or soy withhigh fat content. Moisture introduced via the vegetables helpsgelatinize starches present in the whole grain. External moisturerequirements thus can be effectively reduced for the process operations.The vegetables develop and impart a unique veggie taste in the compositeproduct. The composite products are a convenient form of delivery ofboth whole grains and whole fruits in a ready-to-eat shelf stableproduct. The vegetables and fruits also serve as a natural source ofvitamins and/or minerals, and other nutrients, to reducemacronutrient/micronutrient supplementation needs/costs and provide morebioavailable form of such naturally-delivered nutrients. The wholegrains and real vegetables compliment each other in nutrition, texture,and overall eating properties. Among the health benefits of thecomposite products; they are an excellent source of vitamins (e.g.,Vitamin A via carrots, etc.), minerals, whole grains, good source offiber, low or zero trans fatty acid sources, low saturated fat sources,low or zero cholesterol sources, and can be made with low sodiumcontent, and so forth. Optionally, the composite products also can haveadditionally-added vegetable content incorporated aftershredding/flaking and/or post baking.

In another embodiment, indicated as Option 3 of FIG. 1, a uniqueprocedure is provided for making flaked/shredded products using variouscombinations of whole grains and dairy cheese. Dairy cheese is combinedwith cooked and tempered whole grain particles before completing thepelletizing step of the above-indicated method to provide a shredded orflaked composite product comprising grain material infused with realcheese. The pelletizing process helps in mixing and incorporating cheeseinto the tempered material. Shearing and compaction of the cookedtempered grain and cheese material in the pelletizer softens/plasticizesthe matrix and generates enough of friction/heat to make it pliable andready for flaking or shredding. In view of the soft, pliable attributesof the cheese-infused whole grain pellets, it also is believed that theretrogradation of starch is reversed during this pelletization process.This process also helps in eliminating or minimizing problems associatedwith flaking/shredding grains/seeds and cheese with high fat content.Optionally, the composite cheese-infused whole grain shredded productsalso can have additionally-added dairy cheese incorporated in-betweenthe shreds and/or added on top of the shreds before baking the shreddedproduct. In the matrix or between the shreds or topically on the bakedproduct, vitamins, minerals, herbs/flavors/seasonings, and otheringredients also can be added to further enhance the nutrition, taste,and texture of these whole grain and cheese composite products. Flakedproducts are directly baked after the pelletizing step.

The whole grain and cheese composite products are a convenient form ofdelivery of both whole grains and real cheese in a ready-to-eatshelf-stable product. In a particular embodiment, this method makesflaked/shredded products using a combination of 100% whole grains and100% dairy cheese. The products offers unique nutritional healthbenefits derived both from whole grains and real cheese.

The dairy cheese may comprise Parmesan cheese, Romano cheese, Cheddarcheese, Swiss cheese, and the like and any combinations thereof. In aparticular embodiment, the dairy cheese comprises moisture content belowabout 20 wt %. Higher moisture content cheeses may be difficult toshred, and/or may boil out during baking if added between or on top ofthe shredded layers. Examples of lower moisture content cheeses that maybe used include Parmesan cheese. Suitable dairy cheeses includeso-called natural and aged cheeses produced by treatment of a dairyliquid with a clotting agent such as rennet, or a cheese-making culture,or by developing acidity to the isoelectric point of the casein, or acombination thereof. As known in the cheese making arts, the identity ofthe cheese product, and its characteristic flavor profile, texture andmouthfeel are governed by the particular cheese-making culture(s) orenzyme(s) chosen for the fermentation. The dairy liquid may be ripenedby inoculating it with a starter culture (e.g., a lactic starter forcheddar cheese production) until a desired acidity is reached. Thefermentation mixture can be provided by combining the ripened milk andrennet source, and fermenting the resulting mixture for a time andtemperature sufficient to set the milk. The order of combination ofthese components can be varied. Following fermentation, thevitamin-fortified set milk can be processed in accordance with standardcheese making procedures used to remove whey by-product from the curdand form cheese product from the curd. For example, the set dairy liquidmay be cut, cooked/heated, and whey is separated from the curd. Afterdraining the whey, the curds may be subjected to cheddaring, milling,and salting. The salted curd can be hooped and pressed to removeadditional whey. The desired flavor, aroma and texture of the cheese isobtained by ripening which involves holding the cheese over a period oftime under controlled conditions (e.g., temperature, humidity). The term“ripening” is used herein synonymously with “curing” and “aging.” Thecurd may be dressed, paraffin-coated, and/or packaged before ripening.After ripening, the cured cheese may be cut and directly used, oralternatively wrapped/packaged before use, in the methods of the presentinvention. The dairy cheese also may be commercially obtained.

In another embodiment, indicated as Option 4 of FIG. 1, a uniqueprocedure is provided for making whole grain shredded products enrobedwith chocolate. Baked, shredded products made with pelletized wholegrain, and optionally fruit, in manners generally as described herein,are enrobed with chocolate, cooled, and packaged. These compositeproducts have wholesomeness of whole cereal grains combined withindulgence of chocolate. The texture of these composite products isunique in terms of bite and crunchiness. Multi-textured, multi-flavoredand nutritional enrobed, shredded composite food products are provided.

The chocolate-containing coating used to enrobe the baked shreddedsubstrates can be real chocolate or compound/confectionery chocolatecoating. The enrobing coating may be a standard compound coating used inconfection or nutrition bar production. The chocolate coating can bemade in bitter, bittersweet, light sweet, milk chocolate, and otherimitation versions. Certain flavoring ingredients such as vanilla,vanillin, ethyl vanillin, spices, natural flavoring oils, and nut mealsmay be added to the coatings to further enhance the taste and texture ofthe products. The baked shredded substrates that are enrobed may be madewith 100% whole grains and have all the goodness of whole grains. Thebaked shredded products to be enrobed can be made, e.g., with 100% wholewheat, 100% whole rye, 100% whole rice, 100% whole corn, 100% wholeoats, 100% whole barley, 100% soy or multi whole grain combinations, andso forth. The shredded, baked substrate that is enrobed may be any suchproduct described herein. In a particular embodiment, the baked,shredded substrate that is enrobed is a whole grain or multi-whole grainshredded product including fruit incorporated in accordance with anotherembodiment. These multi-textured composite products have additionalpositive notes of nutrition imparted by the fruit content.Alternatively, a multi-whole grain baked shredded product without fruitcan be enrobed.

In a particular embodiment, various whole cereal grains may be usedsingly or in multi-grain combinations thereof to produce wholegrain-containing shredded or flaked composite products in accordancewith embodiments of the present invention. In one particular embodiment,indicated as Option 5 in FIG. 1, multi-whole grain shredded or flakedproducts are produced containing various combinations of multigrains/seeds. This procedure uses the same generalcooking/tempering/pelletizing/shredding orflaking/forming/cutting/baking procedure described above with referenceto the production of fruit and vegetable composite products but alsoincludes multi-whole grain starting material. This method, as applied tomulti-whole grains, involves cooking different types of grains bypressure cooking in a single stage, then cooling and tempering thecooked material before pelletizing and other post-pelletizing processsteps described herein. All grains are cooked together in one step in apressure cooker. The addition of multi grains in a single step helps tosimplify the processing. The shredded products are made with 100% wholemulti grains and are excellent source of whole grains with all thegoodness of whole grains. The shredded composite products are also agood source of fiber. This method allows shredding or flaking of grainswithin five hours tempering time.

In one embodiment, examples of grains which may be used in theproduction of shredded or flaked composite products of the presentinvention are non-glutenous or low gluten content whole grains such aswhole grain corn or corn kernels, oats or oat groats, barley, rye, rice,triticale, and mixtures thereof. In a particular embodiment, the wholegrains processed using methods of the invention comprise non-glutenousor low-gluten content whole grains, singly or in combinations thereof,which consist of less than about 4 wt %, particularly less than about 3wt %, and more particularly less than about 1 wt %, total gluten contentthereof. A particular whole grain for use in the present invention iscorn. The corn may be of the yellow, white or blue variety or mixturesthereof. High gluten content grains, such as wheat, may also be shreddedor flaked in accordance with methods of the present invention. Forexample, in embodiments of the invention, any whole grain wheat, such aswhole grain soft/hard/durum wheat, or wheat berries may be used alone orin combination with one or more non-glutenous or low gluten contentwhole grains. In embodiments of the invention, whole grains, which areat least partially or fully defatted, such as defatted whole wheatberries, may be used alone or in admixture with full-fatted wholegrains. In the production of multi-grain products, each whole grain maybe employed in equal weight percentages or in different weightpercentages.

The whole cereal grain particles employed may be in the form of the raw,whole, non-comminuted grain or berry or in the form of pre-cut,pre-ground, or comminuted whole grains. For example, the whole grainparticles may be in the form of whole corn kernels, or pre-ground orcomminuted corn kernels. Whole oat particles may be in the form of wholeoat grains or berries, or pre-ground or pre-cut whole oat grains. Thestarch of the whole grain particles employed in the present inventionmay be all or essentially all individual, crystalline starch granules,as determined by light microscopy starch characterization where a sampleis stained with Lugol's Iodine and observed in Brightfield optics.

Although preferred in embodiments, the present invention is not limitedto whole grains as the sole type of grain source that may be used in theproduction of the shredded or flaked composite products. Shredded orflaked composite products also may be made using methods of theinvention from grain sources containing at least in part non-whole grainingredients (e.g., meals, grits, flours, starches, etc.). In addition,products optionally may be made without precooking the composite doughsbefore pelletizing them. That is, the doughs into which the fruit,vegetable or cheese is incorporated in the pelletized intermediatematerial alternatively may be doughs made from flours that are not heattreated, precooked and dried (e.g., masa flour, pregelatinized flour,partially gelatinized flour, presoaked and dried flour, toasted flour,other heat treated uncooked flour, etc.).

In embodiments of the present invention pre-ground or comminuted wholecereal grains are preferred because they hydrate and cook faster thanwhole grains or whole berries. For example, prior to cooking, wholecereal grains, such as whole corn kernels, may be pre-ground, milled orcomminuted to a particle size of less than or equal to about ¼ inch,preferably less than or equal to about 0.2 inch, for example from about0.05 inch to about 0.188 inch. In embodiments of the invention,comminuting, pre-grinding or milling of raw whole grains may be achievedusing a conventional Fitz mill, Commitrol mill, or Urschel mill. Forexample, a Fitz Mill having a ⅛ inch round hole screen may be employedto obtain an average particle size distribution of about: 0.0% on a #6screen, about 14.91% on a #14 screen, about 30.43% on a #20 screen,about 50.25% on a #40 screen, and about 4.41% on the pan.

In embodiments of the present invention, whole seeds or comminuted seedsor legumes, such as soy beans or soy bean grits may be admixed with thecereal grains to enhance protein content of the products of the presentinvention in amount which does not adversely affect shreddability orflakability. Exemplary amounts of the seeds or legumes which may beemployed may range up to about 60% by weight, based upon the totalweight of the whole cereal grains.

In particular embodiments where the whole cereal grains include wholecorn, lime is preferably employed to enhance flavor and also to enhancestarch functionality and cohesiveness. Any food-grade lime or calciumhydroxide may be used in the present invention. The lime may be added inan amount sufficient to improve starch functionality and reducetackiness of the corn-based composition, and to provide a masa flavor tothe final product. Exemplary amounts of lime which may be used inembodiments of the present invention are from about 0.01% by weight toabout 3% by weight, preferably from about 0.1% by weight to about 0.5%by weight, based upon the weight of the whole corn grains or kernels.Lime may be used alone or in combination with other quick cooking agents(such as disodium phosphate).

As can be appreciated from the above descriptions, in particularembodiments indicated in FIG. 1, Option 1 (fruit) may be used alone orin combination with one or both of Option 4 (enrobing) and Option 5(multi-grain); Option 2 (vegetables), or Option 3 (dairy cheese), eachmay be used alone or in combination with Option 5; and Option 4 may beused alone or in combination with Option 1 or Option 5, or as combinedwith both Options 1 and 5; and Option 5 may be used alone, or incombination with any one of Options 1, 2, 3 or 4, or as combined withboth Options 1 and 4.

Shredded or flaked whole grain-containing foods, such as ready-to-eatcereals, crackers, wafers, biscuits, or snack chips, of methods of thepresent invention may be full-fat, reduced fat, low-fat, or no-fatproducts. As used herein, a reduced-fat food product is a product havingits fat content reduced by at least 25% by weight from the standard orconventional product. A low-fat product has a fat content of less thanor equal to three grams of fat per reference amount or label serving.However, for small reference amounts (that is, reference amounts of 30grams or less or two tablespoons or less), a low-fat product has a fatcontent of less than or equal to 3 grams per 50 grams of product. Ano-fat or zero-fat product has a fat content of less than 0.5 grams offat per reference amount and per label serving. For accompanimentcrackers, such as a saltine cracker, the reference amount is 15 grams.For crackers, or biscuits or wafers, used as snacks, and for cookies,the reference amount is 30 grams. Thus, the fat content of a low-fatcracker, wafer, or cookie would therefore be less than or equal to 3grams of fat per 50 grams or less than or equal to about 6% by weightfat, based upon the total weight of the final product. A no-fataccompaniment cracker would have a fat content of less than 0.5 gramsper 15 grams or less than about 3.33% by weight, based upon the weightof the final product. A no-fat wafer having a label serving size of 32grams would have a fat content of less than 0.5 grams per 32 grams orless than about 1.56% by weight, based upon the weight of the finalproduct.

Oleaginous compositions which may be used in producing full-fat, reducedfat, or low-fat shredded products in accordance with the presentinvention may include any known shortening or fat blends or compositionsuseful for baking or frying applications, and they may includeconventional food-grade emulsifiers. Vegetable oils, lard, marine oils,and mixtures thereof, which are fractionated, partially hydrogenated,and/or interesterified, are exemplary of the shortenings or fats whichmay be used in the present invention. Edible reduced- or low-calorie,partially digestible or non-digestible fats, fat substitutes, orsynthetic fats, such as sucrose polyesters or triacyl glycerides, whichare process-compatible may also be used. Mixtures of hard and soft fatsor shortenings and oils may be used to achieve a desired consistency ormelting profile in the oleaginous composition. Exemplary of the edibletriglycerides which can be used to obtain the oleaginous compositionsfor use in the present invention include naturally occurringtriglycerides derived from any vegetable sources such as soybean oil,palm kernel oil, palm oil, rapeseed oil, safflower oil, sesame oil,sunflower seed oil, canola oil, corn oil, olive oil and mixturesthereof. Marine and animal oils such as sardine oil, menhaden oil,babassu oil, lard, and tallow may also be used. Synthetic triglycerides,as well as natural triglycerides of fatty acids, may also be used toobtain the oleaginous composition. The fatty acids may have a chainlength of from 8 to 24 carbon atoms. Solid or semi-solid shortenings orfats at room temperatures of, for example, from about 75° F. to about95° F. may be used. Preferred oleaginous compositions for use in thepresent invention include partially hydrogenated soybean oil, palm oil,and mixtures thereof.

In embodiments of the invention, the amount of vegetable shortening orfat topically applied to shredded products may be reduced by more than25 percent by weight to obtain reduced fat products having, for example,less than about 20% weight percent fat, preferably less than 10% byweight fat, based on the total weight of the baked or fried, finishedproduct.

To provide a more lubricious mouthfeel to reduced fat, low-fat or no-fatproducts, a hydrocolloid gum, preferably guar gum, may be employed tocompensate for the fat reduction as disclosed in U.S. Pat. No. 5,595,774to Leibfred et al., the disclosure of which is herein incorporated byreference in its entirety. As disclosed in U.S. Pat. No. 5,595,774, thehydrocolloid gums are used in effective amounts which provide alubricous, smooth, non-slippery mouthfeel to the baked or fried product.Exemplary amounts of the hydrocolloid gum, preferably guar gum, whichmay be used range from about 0.15% by weight to about 1.5% by weight,preferably from about 0.25% by weight to about 0.45% by weight, basedupon the total weight of the whole berries or grains. Other gums whichmay be used with guar gum include xanthan gum and carboxymethylcellulose, and gums which form gels such as alginate gum, carrageenangum, gum arabic, gum tragacanth, pectin, and locust bean gum, andmixtures thereof. Generally, the greater the extent of shortening or fatreduction, the greater the amount of gum utilized to compensate for theloss of lubricity or loss of smoothness in mouthfeel.

In one method of the present invention, a whole grain shredded or flakedcomposite food product may be produced continuously on a mass productionbasis by admixing whole cereal grain particles with water, andoptionally fruit or vegetables, and pressure cooking the whole grainparticles to at least substantially gelatinize starch of the whole grainparticles, and tempering the cooked, whole grain particles. The cookedand tempered whole grain particles may be pelletized in a pelletizer inthe presence of fruit, vegetables, or dairy cheese to obtain wholegrain-containing pellets, the pelletizing being under pressure andtemperature conditions to provide continuous shreddability of the wholegrain pellets into continuous net-like sheets. The wholegrain-containing pellets may be shredded into whole grain net-likesheets, followed by laminating the whole grain net-like sheets to obtaina whole grain laminate. The whole grain laminate may be cut into wholegrain pieces followed by baking or flying the whole grain pieces toobtain a whole grain-containing shredded composite food product. Inembodiments where a thin, chip-like shredded snack is produced, thewhole grain laminate may be substantially compressed to obtain acompressed laminate having a shredded net-like appearance, followed bycutting the compressed laminate into pieces and baking or frying of thepieces to provide a multi-flavored, nutritional shredded or flakedcomposite food product. In another method, an enrobed, shreddedcomposite food product is produced by pelletizing cooked and temperedwhole cereal grain particles which have undergone retrogradation to ahard, fracturable texture, and optionally in the presence of fruit, toobtain food pellets having a pliable texture, which pellets areshredded, formed into a shredded laminate that is cut or otherwisedivided into discrete shredded food pieces, and then the discreteshredded food pieces are baked to provide baked, shredded foodsubstrates, which are enrobed with a chocolate-containing coating andthen cooled to provide multi-textured, multi-flavored and nutritionalenrobed, shredded composite food products.

The cooking of the grain or berry according to this invention can bedone in any standard cooking equipment, such as a rotary cooker,immersion cooker, or pressure cooker, such as a Lauhoff pressure cooker.Immersion cooking is generally at about atmospheric pressure or onlyabout 2-3 psig. Pressure cooking is preferred because it quicklyachieves full cooking or gelatinization of the whole grain particleswith no, or essentially no white centers The whole grain particles maybe cooked at temperatures and humidities which hydrate and at leastsubstantially gelatinize the internal structure of the grains or berriessuch that only a pin head of white or free starch remains visible in thecenter of the kernel. In embodiments of the invention, the degree ofgelatinization may for example, be at least 90%. In preferredembodiments the starch is essentially 100% gelatinized leaving novisible white centers in the whole grain particles. The degree of starchgelatinization may be measured by differential scanning calorimetry(DSC). Generally, starch gelatinization occurs when: a) water in asufficient amount, generally at least about 25 to 30% by weight, basedupon the weight of the starch, is added to and mixed with starch and, b)the temperature of the starch-water mixture is raised to at least about80° C. (176° F.), preferably 100° C. (212° F.) or more. Thegelatinization temperature depends upon the amount of water availablefor reaction with the starch. The lower the amount of available water,generally, the higher the gelatinization temperature. Gelatinization maybe defined as the collapse (disruption) of molecular order within thestarch granule, manifested in irreversible changes in properties such asgranular swelling, native-crystallite melting, loss of birefringence,and starch solubilization. The temperature of the initial stage ofgelatinization and the temperature range over which it occurs aregoverned by starch concentration, method of observation, granule type,and heterogeneities within the granule population under observation.Pasting is the second stage phenomenon following gelatinization in thedissolution of starch. It involves increased granular swelling,exudation of molecular components (i.e., amylose, followed byamylopectin) from the granules, and eventually, total disruption of thegranules. See Atwell et al., “The Terminology And Methodology AssociatedWith Basic Starch Phenomena,” Cereal Foods World. Vol. 33, No. 3, Pgs.306-311 (March 1988).

Exemplary immersion cooking temperatures may range from about 190° F. toabout 212° F. Immersion cooking of the whole grain particles may occurat about 210° F. at atmospheric pressure using steam for about 30 toabout 36 minutes. The cooking can include a “come-up time” of between6.5 to about 8 minutes during which the temperature of the grain in thevat or cooking vessel is elevated from ambient temperature to thecooking temperature. But preferably, before cooking, the whole grainparticles are added to hot water at a temperature of about 170° to 190°F. in the cooker. The whole grain particles may be added to the hotwater in a rotating cooker, for example, over a time period of about 50to about 100 seconds.

The amount of water used in the immersion cooking step may range fromabout 28% by weight to about 70% by weight based upon the total weightof the grains or berries and added water. The moisture content of thecooked grain, after draining may range from about 29% by weight to about60% by weight, preferably from about 29% by weight to about 42% byweight.

In preferred embodiments, where pressure cooking with direct steaminjection is employed, pressure cooking temperatures may be at leastabout 235° F., preferably at least about 250° F., most preferably fromabout 268° F. to about 275° F. Exemplary pressure cooking pressures mayrange from about 15 psig to about 30 psig, preferably from about 20 psigto about 28 psig with cooking times ranging from about 15 minutes toabout 45 minutes, preferably from about 20 minutes to about 30 minutes.The pressure cooking may include a “come-up time” as in immersioncooking of between 6.5 to about 8 minutes during which the temperatureof the grain in the vat or cooking vessel is elevated from ambienttemperature to the cooking temperature. But preferably, before cooking,the whole grain particles are admixed with hot water at a temperature ofabout 170° to 190° F. in the pressure cooker. The whole grain particlesmay be added to the hot water, or vice versa, in a rotating cooker, forexample, over a time period of about 50 to about 100 seconds. Fruit orvegetables, and other ingredients such as salt and lime in the case ofcorn grain cooking, may be added in the cooker with the water as apre-blend or added separately.

Pressure cooking is preferred over immersion cooking because it providesbetter control over obtaining a desired water content in the cookedwhole grain particles and reduces or eliminates the need for drying ofthe cooked grain particles to achieve a desired moisture content forshredding. Generally, in pressure cooking all of the water added isabsorbed or taken up by the whole grain particles. In addition, steamwhich is directly injected into the pressure cooker condenses and istaken up by the whole grain particles, generally in an amount of about1% by weight to about 3% by weight, based upon the total weight of thecooked whole grain particles. Generally, draining of water afterpressure cooking is not needed because all or substantially all of theadded water and steam condensate is taken up by the cooked whole grainparticles.

The amount of water added in the pressure cooking step, not includingsteam condensate, may range from about 12% by weight to about 30% byweight based upon the total weight of the grains or berries and addedwater. If moisture-containing fruit or vegetables are included in themixture that is cooked, the moisture content thereof can effectivelyreduce external moisture requirements for cooking. The moisture contentof the cooked grain, which includes water inherently present in the rawgrain, after draining if needed, may range from about 29% by weight toabout 42% by weight preferably from about 33% by weight to about 38% byweight, based upon the weight of the cooked whole grain particles.

During cooking, moisture tends to collect on the grain particles orberries. This moisture can increase the stickiness of the cooked grainand can cause handling problems when the grain is transferred to otherapparatus. Mixing the grain in the cooking vat at low rotation speedsprovides for even cooking and reduces lumping.

After draining of any excess cooking water and steam condensate formedduring cooking, the cooked whole grain particles, and any cooked fruitor vegetable portions present, may be discharged from the rotatingcooker and optionally transferred to a surface dryer and cooler. Inembodiments of the invention, the cooked whole grain particles may bedried and cooled to a temperature of less than about 135° F., forexample from about 60° F. to about 85° F. The surface drying and coolingfacilitates flow of the cooked grains as individual, discrete pieces.The dried, cooled whole grain particles may have moisture content offrom about 29% by weight to about 42% by weight, preferably from about33% by weight to about 38% by weight for shreddability into strong,continuous shreds.

In preferred embodiments, the cooked whole cereal grain particles andany other food components present are passed through a lump breaker tobreak apart large lumps or agglomerates of whole cereal grain particles.The de-lumped whole cereal grain particles may then be co-milled toobtain smaller agglomerates of whole cereal grain particles by passingthrough a screen, for example a 1 inch square screen. The co-milledagglomerates may range in size from about golf-ball sized to granularsized, preferably less than about 0.5 cm in diameter.

After cooking, the starch granules of the cooked whole cereal grainparticles are no longer crystalline in nature and are swollen or largerin size, as determined by light microscopy starch characterization usingLugol's Iodine. The cooked particles may contain swollen granules aswell as agglomerated starch clusters.

The cooked whole cereal grain particles, along with any other foodcomponents present, may then be conveyed to a surge bin or grit bin fortempering. The cooked whole grain particles may then be tempered orcured for a sufficient period of time to provide a uniform distributionof the water throughout the cooked whole grain particles. Tempering maybe conducted at a temperature of less than about 135° F., preferablyfrom about 60° F. to about 100° F., more preferably from about 80° F. toabout 90° F. Tempering times may range from about 0.5 hours to about 5hours, preferably from about 1 hour to about 4 hours. The tempering orcuring step may be accomplished in one or more stages. The temperedwhole grain particles may be in agglomerated form, with the agglomeratesranging in size from about golf-ball sized to granular sized, preferablyless than about 0.5 cm in diameter. These agglomerates incorporate andinclude any fruit or vegetable portions present.

In embodiments where a hydrocolloid gum is used, as disclosed in U.S.Pat. No. 5,595,774, the hydrocolloid gum, preferably guar gum, in dry,particulate, or powdered form may be admixed or blended with the cooked,tempered whole grain particles. Batch or continuous mixers or blenderscan be used to mix the gum and the cooked, tempered whole grainparticles or agglomerates to coat them with the gum substantiallyhomogeneously. The dry gum sticks or adheres to the cooked, temperedmoist grains, thus at least partially coating the grains withoutcreating a sticky surface which would hamper or interfere withshredding. Upon pelletizing and shredding of the grains or berries, thegum coating or particles are incorporated into and onto the individualstrands or net-like sheets of dough formed by the shredding rolls.

The cooked, tempered whole grain particles, and any other foodcomponents present, may be transferred by means of belt conveyers to apelletizer for forming them into pellets for shredding or flaking. Uponentering the pelletizer, the tempered whole grain particles may be inthe form of agglomerates. The agglomerates fed to the pelletizer mayrange in size from about golf-ball sized to granular sized, and maypreferably be less than about 0.5 cm in diameter. They may have atemperature of less than about 135° F., preferably from about 75° F. toabout 100° F., more preferably from about 80° F. to about 90° F. Uponentry into the pelletizer, the tempered, whole grain particles may havea hard or rubbery texture. The starch of the tempered whole grainparticles may be retrograded, with the starch being primarily granular,the starch granules being swollen, and some agglomerated starch clustersbeing present, as determined using light microscopy starchcharacterization with Lugol's Iodine.

Commercially available extruders or pelletizers, such as a Bonnet or aWenger pelletizer may be employed to produce the shreddable, whole grainpellets from the agglomerates of cooked, tempered whole grain particlesin the present invention. The pelletizer may be equipped with a solid orcut-flight screw conveyer for conveying and shearing of the temperedwhole grain particles from the input end to the output end and throughthe exit die plate. Cooling jackets are preferably provided to controlthe temperature of the agglomerates in the pelletizer and to control thetemperature of the pellets exiting the pelletizer. The cooling jacketshelp to remove heat generated by the shearing action occurring in thepelletizer and at the die plate as the agglomerates are forced throughthe die plate apertures.

The pelletizer may be equipped with an internal knife installed on theupstream side of an exit die plate, and an external knife installed onthe downstream side of the exit die plate for forming the whole grainagglomerates into a rope or rod which is cut into whole grain pellets.In embodiments of the invention, the die plate may have a plurality ofholes or apertures each having a diameter of about 3/16 inch to about5/16 inch. The open area of the die plate, or the total area of theapertures as a percentage of the die plate area, may range from about14% to about 55%, preferably from about 25% to about 45%, morepreferably from about 38% to about 42%.

The whole grain pellets may be produced with dimensions for shredding onconventional shredding equipment. For example, the pellets may have acut length of about ⅛ inch to about ¼ inch, and a diameter of about 3/16inch to about 5/16 inch imparted by the die apertures.

In accordance with the method of the present invention, the pelletizingpressure, as measured at the die plate, may be from about 200 psig toabout 700 psig, preferably from about 400 psig to about 500 psig. Thepressures and temperatures employed preferably result in no orsubstantially no expansion of the extrudate exiting the die orifices.Also, the temperature of the pellets exiting the pelletizer should besufficiently low so that any increase in temperature caused by theshredding operation does not result in deleterious sticking of theshreds to the downstream shredding rolls or compacting rolls.

Generally, the temperature of the shredded product out of the shreddingrolls may be up to about 120° F. to about 135° F. without substantialsticking problems. The pelletizing temperature may be controlled by useof the cooling jackets to provide a pellet temperature of from about 80°F. to about 135° F., preferably from about 90° F. to about 110° F., forexample from about 90° F. to about 110° F., for example from about 95°F. to about 105° F., upon exiting the pelletizer die plate. Inembodiments of the invention, cooling air may be supplied at the exit ofthe plate to cool the exiting pellets to help avoid stickiness problems.

The pellets exiting the pelletizer have a soft, pliable, cohesivetexture. The pelletization is believed to reverse retrogradation of thetempered whole grain particles. High shear in the pelletizer, it isbelieved, substantially fractures retrograded starch granules andreleases amylose and amylopectin to increase cohesiveness forshreddability into continuous net-like sheets. While the starch enteringthe pelletizer may be primarily granular, it may be quite different inthe pellets exiting the pelletizer. The starch of the whole grainpellets produced by the pelletizer is primarily agglomerated starch andfragmented starch with only a small population of individual granules,as determined using light microscopy starch characterization withLugol's Iodine.

Upon exiting the pelletizer, the cooling of the pellets should not be soextensive, and the pellets should not be permitted to sit or temper toolong, so as to induce substantial starch retrogradation or pellethardening which may impede shreddability.

In addition to the use of a pelletizer, other means, such as doubleshredding, may be employed to shear the cooked, tempered, hardened wholecereal particles into soft, pliable, cohesive shreddable pieces. Indouble shredding, the hardened particles are first shred intodiscontinuous shreds, and then the discontinuous shreds are shred intocontinuous shreds. However, use of a pelletizer is preferred for moreefficient production of continuous shreds.

The whole grain-containing pellets may preferably be immediately orquickly, for example within about 20 minutes, preferably within about 10minutes, transported to a shredding or flaking operation so as to avoidany substantial hardening of or skin formation on the soft, pliablepellets. In embodiments of the invention, the whole grain pellets may betransferred by means of pneumatic conveyors or belt conveyors and/orbucket elevators to a hopper which feeds a screw conveyor. The lattermay transfer the whole grain pellets to a series of shredding rolls ormills via flow tubes or hoppers or pneumatic conveyors. An example ofsuch a screw conveyor is that made by the Screw Conveyor Corporation,704 Hoffman Street, Hammond, Ind. 46327. The moisture content of thewhole grain-containing pellets for shredding may range from about 29% byweight to about 42% by weight, preferably from about 33% by weight toabout 38% by weight, based upon the weight of the pellets, forshreddability into strong, continuous shreds.

Any conventional milling system can be used in the present invention. Aconventional milling system for making a wafer or biscuit may beemployed in producing the shredded products such as ready-to-eatcereals, biscuits, and snack chips in accordance with the presentinvention. The conventional milling system can comprise a pair ofclosely spaced rolls that rotate in opposite directions with at leastone of the rolls having circumferential grooves. Upon passing betweenthe rolls, the dough is formed into long individual strings or strands.A circumferentially grooved roll can also be grooved transversely to thecircumferential grooves for the production of a net-like sheet. Whensheets are formed, the sheets are comprised of interwoven shreds orstrings. When the rolls are held tightly together, the shreds orfilaments partially separate from each other but are more or lessconnected. When the rolls are sprung slightly apart under pressure, theadjacent filaments can be united to each other by very thin webs or finswhich stretch between them.

Upon passing between the rolls, the dough is deformed into thecircumferential grooves and the optional crosshatching grooves. Eachpair of rolls produces dough layer having a plurality of generallyparallel longitudinal strands and optionally a plurality ofcrosshatchings generally perpendicular to the strands. Thecrosshatchings and the longitudinal strands form an integral net-likesheet. The texture of each layer may be controlled by the number ofcrosshatchings in each layer forming the net-like sheets. The net-likesheets are preferably unwebbed or webless, i.e., the crosshatchings andlongitudinal strands of each layer are not connected by a membrane. Theuse of an open space within the area formed by the longitudinal strandsand the crosshatchings in the outer layers provides a more attractiveproduct. Additionally, use of the open space in the inner layers avoidsan excessively dense texture.

The longitudinal strands are produced by the circumferential grooves andmay run in parallel with the direction of movement of an underlyingconveyor. The crosshatchings of the dough layer are produced by thecrosshatching grooves and may run generally perpendicular to thedirection of movement of the conveyor.

The shredding mills may be arranged in a linear series along the commonunderlying conveyor. Each of the shredded dough layers or sheets may bedeposited on the conveyor in super-position, with their longitudinalstrands running in the same direction.

Conventional shredding systems which can be used in the process of thepresent invention are disclosed in U.S. Pat. Nos. 502,378; 2,008,024;2,013,003; 2,693,419; 4,004,035; and U.S. Pat. No. 6,004,612; andCanadian Patent No. 674,046.

The first and last one or more shredded dough layers to be deposited orlaminated may have a number of crosshatchings so as to provide a regionof denser texture or higher density in the biscuit or chip. The firstlayer which is laid down upon the conveyor belt preferably has asufficient number of crosshatchings to provide a more stable bed for thedepositing of subsequent shred layers. Additionally, the outsideappearance of the product is enhanced by the presence of crosshatchingsas is the initial impression of crispness upon eating. For a 5 inchdiameter shredding roll, the number of crosshatchings may be about 45 ormore, equally spaced about the roll. Five inch diameter rolls maygenerally have: (1) about 10 to 22 circumferential grooves per inch, and(2) up to about 120 equally spaced crosshatching grooves. Larger orsmaller diameter rolls may also be used with about the same frequency ofgrooves as the five inch diameter rolls.

The dough layers which are deposited between the outer layers providinga denser texture or higher density may have a decreased number ofcrosshatchings so as to provide a region of lighter texture or lowerdensity in the interior of the chip. The number of cross-hatchings ineach layer may be the same or different.

In at least one embodiment of the invention, at least 30 percent of thetotal number of net-like sheets may provide one or more regions of densetexture or higher density. In preferred embodiments, each layer has thesame number of cross-hatchings. In at least one embodiment of theinvention, for increased durability; crispness, and visual appearance,120 crosshatchings for a five inch diameter roll is preferred.

The depth of the circumferential and cross-hatching grooves of theshredding rolls may be from about 0.010 inch to about 0.10 inch,preferably from about 0.016 inch to about 0.075 inch. For example, inpreferred embodiments the cross-hatching groove depth may be about 0.018inch and the circumferential groove depth may be about 0.075 inch.Groove depths of less than about 0.010 inch tend to require too manylayers to achieve a desired weight per piece. The net-like sheets whenlaminated upon one another, do not necessarily line up exactly so thatone layer is superimposed exactly on another layer. The greater thenumber of layers, the more likely the openings in one net-like sheetwill be at least partly covered by the shreds of another net-like sheet.Thus, increasing the number of layers to achieve a given piece weighttends to result in a denser laminate and loss of shred integrity uponcompression in compression rolls. The use of groove depths greater thanabout 0.10 inch tends to result in too dense of a laminate which isdifficult to bake or fry into a crisp, chip-like texture.

Generally, the total number of net-like sheets may range from one to 21depending upon the type and size of shredded product. For example, largesized ready-to-eat breakfast cereal biscuits or wafers may contain fromabout 1 to about 21 net-like sheets, preferably from about 1 to about 21net-like sheets. Smaller sized ready-to-eat cereal biscuits or wafersmay contain from 1 to 7, preferably from 1 to 6 net-like sheets. Thesnack chips of the invention may have 1 to 7, preferably 1 to 5, mostpreferably 4 net-like sheets. If the number of sheets is less than two,continuous, consistent production tends to be disrupted. The laminatetends to stick to or slip on the belt or compression roll uponsubstantial compression of a laminate which is relatively thin prior tocompression. Additionally, with too few layers, the fried or bakedproduct tends to be too fragile for handling on mass productionpackaging equipment or for dipping. If the number of sheets or layers isgreater than seven, upon compression to achieve a desirable, chip-likethinness, the laminate becomes too dense and difficult to bake or fryinto a crispy texture. In addition, excessive compression may result ina loss of a distinctive, shredded appearance.

In at least one embodiment of the invention for producing a shreddedwhole grain-containing snack chip, or a thin, crisp ready-to-eatbreakfast cereal, the whole grain laminate prepared via shredding may becompressed in accordance with the method and apparatus of U.S. Pat. No.6,004,612 to Andreski et al. for “Production of Shredded Snacks withChip-Like Appearance and Texture”, the disclosure of which is hereinincorporated by reference in its entirety. The apparatus and method ofU.S. Pat. No. 6,004,612, may be used to obtain a whole grain shreddedchip-like snack having a substantially uniform shredded net-likeappearance and crisp, shredded texture by substantially compressing alaminate of whole grain net-like sheets of whole grain pellets obtained“in accordance with the present invention. As disclosed in U.S. Pat. No.6,004,612, the compression substantially reduces or eliminates airpockets or interlayer spacing and enhances interlayer adhesion so as toprevent the development of a puffed, pillowed, or thick biscuit orcracker-like appearance. Even though the laminate undergoes substantialcompression, substantially flat, unpuffed, chip-like products exhibit asubstantially uniform shredded, net-like appearance upon their majorsurfaces. Additionally, individual shred layers are visually discerniblein the baked or fried product when it is broken and viewed incross-section. The strength of the laminate is sufficient tocontinuously undergo cutting, transferring, and packaging operationsduring mass production without tearing or breaking. Baked or friedchip-like shredded snacks are sufficiently strong for dipping into andscooping of dips or sauces without breaking. Additionally, chips madeaccording to this process have a whole grain appearance, with portionsof the hull or bran of the whole grains being visually apparent innumerous locations on the surface of shredded snack chips.

In embodiments of the invention, prior to compression, the thickness ofthe whole grain laminate may generally range from about 0.035 inch toabout 0.20 inch. Generally, the thickness of the laminate is reduced byat least about 35%, generally from about 45% to about 60% of itsthickness prior to compression. As disclosed in U.S. Pat. No. 6,004,612,compression of the laminate to substantially reduce its thickness may beachieved by passing it between at least one pair of counterrotatingcompression rolls while it is supported upon and transported by aconveyer belt. Where more than one pair of compression rolls areemployed, the total thickness reduction may be approximately equallydivided between the pairs of rolls. Use of a single pair ofcounterrotating compression rolls is preferred for achieving thesubstantial compression of the laminate.

Supporting the laminate upon a belt while it is being compressed helpsto avoid excessive stretching and tearing or sticking of the laminateduring compression and transport through the rolls. As disclosed in U.S.Pat. No. 6,004,612, each pair of counterrotating rolls may comprise atop roll which contacts the top surface of the laminate, and a bottomroll which contacts the bottom surface of the conveyer belt whichsupports the laminate. The nip or gap between the counterrotating rollsand their relative rotational speeds are set so as to substantiallycompress the laminate while avoiding: 1) substantial sticking of thelaminate to the upper roll, or 2) substantial movement or slippage ofthe laminate relative to the belt, either of which would substantiallydisrupt or distort the shred pattern of the laminate as it iscompressed. The bottom roll helps to maintain the linear speed of theseparately driven conveyer belt as the top roll compresses the laminateagainst the top surface of the belt. The rotational speeds of the topand bottom rolls of a pair of counterrotating rolls may be at leastsubstantially the same, or essentially the same, depending upon therelative diameters of the rolls. If different diameter rolls are used,their rotational speeds, or angular velocities, may be adjusted toprovide at least substantially the same linear velocity.

As disclosed in U.S. Pat. No. 6,004,612, the laminate is compressed bythe counterrotating rolls without cutting of the laminate or withoutmolding of the laminate into individual pieces. The compression orthickness reduction is at least substantially uniform across the widthof the laminate. The compression provides a thin, cooked, but dough-likecompressed laminate and helps to prevent substantial puffing orexpansion upon subsequent baking or frying. The thickness of thecompressed laminate exiting the nip of the compression rolls is such soas to provide a thin, chip-like appearance upon baking or frying.

In embodiments of the present invention, generally the thickness of thecompressed laminate may range from about 0.05 inch to about 0.12 inch,preferably from about 0.06 inch to about 0.10 inch, for example fromabout 0.07 inch to about 0.09 inch.

Even though the thickness of the laminate is substantially reduced, asubstantially uniform shred pattern is visually apparent upon theopposing major surfaces of the baked or fried product. Additionally, atleast substantially all, or all of the individual shred layers aregenerally visible to the naked eye upon breaking a baked or fried pieceperpendicularly to its major surfaces. For example, if a baked or friedpiece is broken in about half, a cross-sectional viewing of each piecemay generally reveal the same number, or substantially the same number,of shred layers or net-like sheets as were present prior to compression.

The moisture content of the laminate prior to compression and aftercompression is generally at least substantially the same. Moisturecontents of the laminate prior to and after compression may range fromabout 29% by weight to about 42% by weight, preferably from about 33% byweight to about 38% by weight. The starch of the laminates may be in theform of agglomerated starch clusters with virtually no individual starchgranules, as determined using light microscopy starch characterizationwith Lugol's Iodine.

The whole grain laminates of shredded dough strands, layers or net-likesheets may then be cut, and slit using conventional equipment, such asrotary cutters and slitters. Dockering of the laminate is not necessaryto prevent puffing or leavening. For at least one embodiment of theinvention, a non-dockered piece is preferable because it is morechip-like in appearance. Also, dockering of a compressed laminate tendsto produce excessively dense portions which are difficult to bake or fryout without scorching.

The cutting operation may partially or completely cut the whole grainlaminates into strips. The slitting operation may completely cut orscore the strips so as to provide scored strips of unbaked or unfriedready-to-eat cereal biscuits or snacks with the unbaked or unifiedbiscuits or snacks tenuously connected to each other. In embodiments ofthe invention, the non-compressed or the compressed whole grain laminatemay be edge trimmed and then partially cut into shaped pieces by arotary cutter without substantial generation of scrap or recyclematerial. Then, the partially-cut laminate may be cut longitudinally inthe direction of movement of the conveyer belt, and then transversely tothe direction of movement of the conveyer belt without substantialgeneration of scrap or recycle material. After baking or frying andbefore or after oil or seasoning addition to the strips, the conveyormovement, etc., breaks apart the scored strips to provide individualpieces of shredded product such as ready-to-eat cereals, biscuits,wafers, or chip-like snacks.

The shape of the shredded products may be square, round, rectangular,elliptical, parallelepiped, triangular, jig saw puzzle shapes and thelike. Shapes which minimize or eliminate waste or recycle are preferred.A most preferred shape-for a chip-like snack is a triangular orsubstantially triangular shape. As disclosed in U.S. Pat. No. 6,004,612,to essentially eliminate waste, the triangles may be formed using arotary cutter which cuts the compressed laminate so that the base ofeach triangle is parallel to the longitudinal axis or direction ofmovement of the laminate. To reduce breakage during and after cutting,the laminate is preferably cut so that the apex or point of a trianglein one row does not touch or intersect the apex or point of anothertriangle located in an adjacent row. In preferred embodiments, thecutter may cut the laminate into a plurality of longitudinal rows oftriangular-shaped pieces so that the apex of a triangular piece of onerow is located at or intersects about the midpoint of the base of atriangular piece of an adjacent row as shown in U.S. Pat. No. 6,004,612.

As disclosed in U.S. Pat. No. 6,004,612, it is also preferable to formor cut the triangular pieces with rounded, blunted or flat corners so asto eliminate sharp points which may break-off during rotary cutting orsubsequent slitting or transferring of the cut laminate. For example,vacuum may be used for lifting and transferring a partially cut laminatefrom one conveyer belt to another. The presence of substantial amountsof broken-off points may clog the vacuum equipment. One or more,preferably all three corners or apexes of the triangular pieces may berounded, flattened or blunted. For example, to obtain flattened orblunted corners on a substantially equilateral or isosceles triangularshaped piece, each corner may be formed, cut, or shaped at leastsubstantially parallel to its opposing side or at least substantiallyperpendicular to an adjacent side by the rotary cutter.

The cut, whole grain laminate obtained via the shredding process routemay be dried, baked, fried, and/or toasted in conventional equipment.Suitable ovens for drying, baking and toasting the cut laminate includeProctor & Schwartz, Wemer-Lehara, Wolverine and Spooner ovens containingforced air and gas fired burners and a conveyor. Suitable equipment forfrying include Heat and Control, FMC/Stein oil flyers. The laminates maybe toasted to enhance the flavor and brown the edges of the shreddedproducts. Baking or frying of compressed laminates does notsubstantially puff or leaven them and provides a substantially flat,thin, chip-like appearance.

Temperature profiles used for drying, baking, frying and toasting of thelaminated preforms may generally be within the range of about 200° toabout 700° F. The baking is preferably performed in a zoned oven usinglow oven velocity to avoid excess curling, separating or warping of thestrips during baking. The total time for drying, baking, frying and/ortoasting may be such so as to avoid browning (except on the edges of thepieces). It depends upon the number of shred layers, the size of theshredded product and the type of oven. The total time for drying,baking, frying and/or toasting may range from about 1 minutes to about10 minutes. The cut, whole grain laminate may be fried and toasted inconventional frying and toasting equipment Heat and Control of Hayward,Calif. and FMC/Stein of Sandusky, Ohio make suitable fryers, which mayhave direct or indirect heated oil and a conveyor. The temperatureprofiles used in the fryer for frying and/or toasting may generally bewithin the range of 300° F. to 400° F. The total time for frying and/ortoasting is preferably less than 3 minutes, and the final moisture ofthe resulting product is typically about 1-3% by weight. If the moistureof the resulting product is above about 3% by weight, then crispness maysuffer; and if the moisture is less than about 1% by weight, then theproduct may have excessive oiliness, a darker color, and a scorchedflavor. After baking or frying, the starch of the products may be in theform of agglomerated starch clusters with virtually no individual starchgranules, as determined using light microscopy starch characterizationwith Lugol's Iodine.

The flakes obtained from the flaking process route may be baked viatoasting by suspending them in a hot air steam, rather than by layingthem onto a flat baking surface, in a generally conventional manner. Theovens used for toasting the flakes may be sloped from the feed end tothe discharge end, and are perforated on the inside to allow air flow.These perforations usually are large as possible for good air flow butsmall enough so that flakes cannot catch in them. The toasted flakes arethen cooled and sent to packaging.

The color of the final baked or fried shredded or flaked product may bea substantially uniform off white to golden tan color. The product maybe topped with salt (for example, 0.5 to 2 weight percent, based on thetotal product weight) prior to baking or frying. The salt providesflavor and flavor enhancement. Some of the salt (NaCl) can be replacedwith KCI or other salt substitutes.

Fat or shortening, when used in embodiments of the invention can beapplied, preferably by spraying in oil form, to the top and bottomsurfaces of baked or fried strips of snacks having no added fat orhaving only fat inherent in the cereal grain. For example, whole wheatberries generally have an inherent fat content of about 2% to 4% byweight. See, Wheat: Chemistry and Technology, Vol. II, Pomeranz, ed.,Amer. Assoc. of Cereal Chemists, Inc., St. Paul, Minn., p. 285 (1988).In embodiments of the invention, the topical application of oil to bakedor fried snacks having no other added fat may result in baked or friedproducts having a total fat content of less than about 20% by weight,preferably less than about 10% by weight. In other embodiments theamount of topically applied oil may be less than about 8% by weight, forexample less than about 6% by weight, based upon the weight of achip-like, shredded snack. Use of a hydrocolloid gum provides forobtaining a slippery or smooth mouthfeel and a glossy appearance evenwith no added fat.

Whole grain shredded or flaked composite products of the presentinvention may contain one or more additives (e.g., vitamins, minerals,colorants, flavorants, etc.) at effective levels of concentration.Exemplary thereof are sugars such as sucrose, fructose, lactose,dextrose, and honey, polydextrose, dietary fiber, seasonings, such asonion, garlic, parsley/other herbs, and bouillon, malt, wheat germ,nuts, cocoa, flavorants such as fruit flavoring, cracker flavoring,cinnamon, and vanilla flavoring, any acidulants such as citric acid,lactic acid, malic acid and other preservatives such as TBHQ,antioxidants such as tocopherol and BHT, food colorant, emulsifiers suchas Myvatex 7 (a blend of distilled monoglycerides manufactured byEastman Kodak), sodium stearoyl lactylate, lecithin, and polysorbate 60,and vitamins and/or minerals. Examples of suitable vitamins and mineralsinclude B-complex vitamins, soluble iron compounds, calcium sources suchas calcium carbonate, vitamin A, vitamin E, and vitamin C. Also, non-fatdry milk solids. (i.e., milk powder) or soybean protein may be added inan amount sufficient to create a final protein level of from about 10 toabout 20 weight percent. Such additional ingredients may range up toabout 30 weight percent, based on the total dry weight of the finalproduct.

Additives, such as vitamins and minerals, may be dry blended with anoptional hydrocolloid gum and then the dry blend may be admixed with thecooked; tempered whole grain particles. In other embodiments, enrichmentwith vitamins and minerals and/or other additives may be achieved byblending with the blended grain and optional gum mixture. For example, adry multi-vitamin premix may be added with simultaneous mixing to a gumcoated grain mixture at the entry of a screw conveyor to form ahomogeneous composition. The resulting composition may be fed or droppedinto a hopper, which supplies milling rolls. The multi-vitamin andoptionally gum-coated grain composition may then be milled in shreddingrolls and formed into shredded products.

Additives or fillings, particularly those which may adversely affectshredding, may also be incorporated into the shredded baked or friedgoods of the present invention by depositing them between shred layersduring formation of the dough laminate. For instance, salt, sucrose,fructose, lactose, dextrose, polydextrose, fiber, milk powder, cocoa,and/or flavorants are exemplary of additives which may be deposited onthe baked or fired goods. Exemplary fillings for inter-shred layerdeposition include fruit paste fillings, vegetable paste fillings,no-fat cheese powder fillings, confectionery fillings, and the like. Theadditives or fillings may be full-fat, no-fat, reduced-fat or low fat.

Additives may also be topically applied to the laminated structurebefore or after baking or frying. For instance, seasonings, oils,flavorants, fortifying agents, and/or preservatives may be topicallyapplied to the baked or fried goods. In the production of whole grainshredded snacks, additives are preferably topically applied rather thanapplied between layers so as to not adversely affect a thin, chip-likeappearance. Topically applied oil may be used as a carrier for one ormore additives, such as flavorants or seasonings. Topical application ofadditives may be achieved using conventional dispensing apparatus suchas disclosed in U.S. Pat. No. 5,707,448 to Cordera et al., for Apparatusfor the Application of Particulates to Baked Goods and Snacks, and thedisclosure of which is herein incorporated by reference in its entirety.

As indicated in FIG. 1, an alternative process route toshredding/forming/cutting is flaking. Flaking can be performed on thepellets exiting the pelletizer station using conventional equipmentgenerally used for flaking whole grain pellets in cereal flakeproduction and the like. For instance, the pellets can be conveyedbetween pairs of very large metal rolls that press them into very thinflakes. As other alternatives, the pellets also may be puffed. Forexample they may be gun-puffed, such as by using conventional manualsingle-shot guns, automatic single-shot guns, automatic multiple shotguns, or continuous guns, used for gun-puffing cooked whole grains incereal production. The pellets also may be oven-puffed, particularly ifthe whole grain content comprises cooked rice and/or corn, which caninherently puff in the presence of high heat and proper moisturecontent. The puffed products can be directly packaged, or may beseasoned, fortified with vitamins/minerals, and/or coated withpreservative before packaging. In other embodiments, production offilled products or half products using the pellets also may be provided,e.g., by feeding the pellets to a dual extruder in which the pellets maybe used to form an enrobing layer that is filled with a different foodmaterial.

Shredded or flaked composite products of the present invention may havea moisture content of less than about 5% by weight, preferably about 0.5to about 3 wt. %, more preferably about 1 to 2 wt. %, based on the totalweight of the baked or fried, finished product. The final product may bebaked or fried to a shelf stable relative humidity or “water activity”of less than about 0.7, preferably less than about 0.6. It may have ashelf stability of at least about 2 months, preferably at least about 12months, when stored in proper, sealed packaging.

The following examples further illustrate the present invention whereinall parts and percentages are by weight and all temperatures are in of,unless otherwise indicated.

EXAMPLE 1 Multi-Whole Grain Shredded Snack

The ingredients and their relative amounts that may be used to produce athin, crisp, chip-like, multi-whole grain shredded snack are:

Amount Ingredient (Weight %) Pre-ground whole wheat (about 13% by weightwater) 17.35 Pre-ground whole brown rice (about 13% by weight water)17.35 Pre-ground whole oat groats (about 13% by weight water) 17.35Pre-ground whole yellow corn (about 13% by weight water) 17.35 Salt 0.19Water 30.41 TOTAL 100.00

A pre-ground multi-whole grain combination may be prepared by separatelyFitzmilling the raw whole grains using a ⅛ inch round holes screen.Whole white corn or any other colored whole corn may be used instead ofwhole yellow corn for these examples. The water and salt may be premixedand added to a Lauhoff rotary steam pressure cooker. The watertemperature may be about 170° F.-190° F. Then, all the Fitzmilledmulti-whole grains may be incorporated into the pressure cooker at thesame time in one step. The four pre-ground whole grains may bepreblended or separately added to the pressure cooker at the same time.A substantially homogenous or uniform blend of the grains is preferablyused. The mass in the cooker may then be heated with steam and cookedfor about 15-30 minutes at a pressure of about 12-26 psig and atemperature of about 268° F. to about 275° F. to fully gelatinize thestarch of the whole grain particles.

The cooked whole grain corn particles may then be discharged from therotating cooker, and the cooled cooked material is Comilled using a 1inch square screen to obtain small grits. The small grits may then beconveyed to a grit bin or curing (tempering) tank. The cookedmulti-whole grains may be tempered in the grit bin for 1-3 hours, with atarget tempering time of about 2 hours. The cooked, tempered whole grainparticles may have a moisture content of about 35% by weight to about38% by weight for shredding.

The cooked tempered multi-whole grains may be transferred to a Bonnetpelletizer having a solid or cut flight screw, internal and externalknives, and a die plate having ¼ inch or 5/16 inch apertures and an opendie area of about 38% to about 42%. The tempered grits may be formedinto pellets at a pressure of about 450 psig to about 700 psig. Thepelletizer cooling unit may be set to about 40° F. to cool the jacket ofthe pelletizer so the pellets exiting the pelletizer have a pellettemperature of about 105° F. to avoid potential stickiness issues at thedownstream shredder, triangular cutter head, and smooth compressionroll. Air may be introduced at the die cutter to disperse the pellets.The multi-whole grain pellets obtained from the pelletizer are soft,pliable and coherent, and may have a length of about ⅛ inch to about ¼inch and a diameter of about ¼ inch to about 5/16 inch.

The discrete, free flowing multi-whole grain pellets may then beconveyed to a surge hopper for feeding to one or more shredding millswhich are arranged in a linear series along a common conveyor. Eachshredding mill may comprise a pair of counterrotating rolls held inmutual contact for the production of net-like sheets. The rolls of themills may each have a groove depth of about 0.018 inch to 0.021 inch and120 cross-hatching grooves.

The net-like cereal dough sheets produced by the shredding mills may becontinuously deposited upon a continuous conveyor belt to form amulti-layer, e.g., four layer, whole grain laminate having a thicknessof about 0.06-0.10 of an inch. While supported on the conveyer belt, themulti-layer laminate may be continuously compressed between smoothsurfaced, non-grooved, stainless steel counterrotating compressionrolls, such as disclosed in U.S. Pat. No. 6,004,612, to producechip-like snacks. The compression rolls may have the same diameter andmay be driven by a common drive at the same rotational speed. The linearspeed of each compression roll may be the same and the linear speed ofthe belt may be about 1% slower than the linear speed of the compressionrolls. The compression rolls may be moved or maintained in position bythe use of air cylinders. Air cylinder pressures of about 60 psi to 80psi may be used to maintain a desired gap between the rolls as the beltand laminate continuously pass between the counterrotating compressionrolls. The gap between the upper roll surface and the top surface of theconveyer belt may be from about 0.06 inch to about 0.08 inch to obtain acompressed laminate having a thickness of about 0.06 inch to about 0.10inch. The moisture content of the laminate prior to compression and themoisture content of the compressed laminate may be about 35% by weightto about 38% by weight.

The compressed multi-layer laminate is cut into discrete pieces of adesired shape and size. For example, the compressed laminate may beconveyed to an edge trimmer to trim the longitudinal edges. The trimmed,compressed laminate may then be conveyed to a rotary cutter having aplurality of circumferential rows of Teflon 7 coated triangular cuttingor forming elements. The elements may partially cut or form thecompressed laminate into rows of isosceles triangle shaped preforms, orother shaped preforms, having blunted or flattened corners. Thetriangular preforms are joined at their peripheries by a thin layer ofdough resulting from only partially cutting or scoring of the compressedlaminate. The partially cut compressed laminate may then be cut or slitlongitudinally, and then cut transversely to the direction of movementof the laminate to form strips of scored, triangular dough preforms.

The multi-whole grain compressed laminate preforms may be transferred toa multizone band oven for drying, baking and toasting for about 1 to 7.5minutes at temperatures ranging from about 200° F. to about 700° F. Thebaked product leaving the oven may have an end point moisture content ofabout 2% by weight, based upon the weight of the final product.

After exiting the oven, the baked product strips may be oiled andseasoned in a seasoning drum or tumbler. Soybean oil or other vegetableoils may be topically applied as a fine spray to the top and bottom ofthe baked snack preform strips, followed by the application of sweet orsavory seasonings.

The baked preform strips may then be conveyed to packaging in a mannerso that the scored strips of triangular snacks readily separate at thescore line by motion, bumping, etc., into individual snack pieces. Thesnack pieces may be, e.g., isosceles triangle shaped with blunted orflattened corners. The base may be about 1.7 inches long or 2.54 inches,and the two sides may each be about 1.6 inches long or 2.60 inches long.The two blunted side portions perpendicular and adjacent to the base mayeach be about 0.1 inch long. The blunted side portion parallel to andopposite the base may be about 0.16 inch to about 0.30 inch long. Thethickness of the baked snack piece may be about 0.08-0.16 inch. Thebaked snack pieces may have a thin, flat, chip-like appearance andcrisp, chip-like texture. The top and bottom major surfaces may have asubstantially uniform shred pattern or embossed or woven, shreddedappearance and texture. Upon breaking the baked snack chips, themultiple (e.g., four) shred layers may be seen by the naked eye incross-section. The snack chips may be used for hand-to-mouth snackingand may be used for dipping without breakage.

EXAMPLE 2 Whole Grain Shredded Snack Enrobed with Chocolate

The ingredients and their relative amounts which may be used to producea thin, crisp, chip-like, whole grain rice shredded snack are:

Amount Ingredient (Weight %) Pre-ground brown rice (about 13% by weightwater) 73.89 Salt 0.25 Water 25.86 TOTAL 100.00

The pre-ground whole brown rice (regular or parboiled) may be preparedby Fitzmilling raw whole grain brown rice using a ⅛ inch round holesscreen. The whole grain rice may be small, medium, or long grain ricetype. The water and salt may be pre-mixed and added to a Lauhoff rotarysteam pressure cooker. The water temperature may be about 170° F.-190°F. Then, the Fitzmilled whole rice may be added to the rotating cookerwithin about 60-70 seconds. The mass in the cooker may then be heatedwith steam and cooked for about 12-30 minutes at a pressure of about12-26 psig and a temperature of about 268° F. to about 275° F. to fullygelatinize the starch of the whole grain rice particles.

The cooked whole grain rice particles may then be discharged from therotating cooker, and the cooled cooked material is then Comilled using a1 inch square screen to obtain whole grain rice small grits. The smallgrits may then be conveyed to a grit bin or curing (tempering) tank. Thecooked whole grain rice grits may be tempered in the grit bin for 1 to 3hours, with a target tempering time of about 2 hours. The cooked,tempered whole grain rice grits may have a moisture content of about 35%by weight for shredding.

The cooked tempered whole grain rice grits may be transferred to aBonnet pelletizer having a solid or cut flight screw, internal andexternal knives, and a die plate having 3/16 inch apertures and an opendie area of about 38% to about 42%. The tempered agglomerates may beformed into pellets at a pressure of about 450 psig to about 700 psig.The pelletizer cooling unit may be set to about 40° F. to cool thejacket of the pelletizer so the pellets exiting the pelletizer have apellet temperature of about 95° F. to about 105° F. to avoid potentialstickiness issues at the downstream shredder, triangular cutter head,and smooth compression roll. Air may be introduced at the die cutter todisperse the pellets. The whole grain pellets obtained from thepelletizer are soft, pliable and coherent, and may have a length ofabout ⅛ inch to about ¼ inch and a diameter of about 3/16 inch.

The discrete, free flowing whole grain pellets may then be shred into awhole grain laminate, compressed, rotary cut, baked, and optionallyseasoned, as in Example 1. The baked product (or baked and seasonedproduct) may then be enrobed with real chocolate coating or compoundchocolate coating, or a combination of both. The baked product:chocolatecoating ratio may be 50:50 to 40:60 wt %:wt %, respectively. The enrobedbaked product can be packaged, such as described in Example 1.

EXAMPLE 3 Multi-Whole Grain and Cheese Shredded Snack

The ingredients and their relative amounts that may be used to produce athin, crisp, chip-like, multi-whole grain and cheese shredded snack are:

Amount Ingredient (Weight %) Pre-ground whole wheat (about 13% by weightwater) 17.35 Pre-ground whole brown rice (about 13% by weight water)17.35 Pre-ground whole oat groats (about 13% by weight water) 17.35Pre-ground whole yellow corn (about 13% by weight water) 17.35 Salt 0.19Water 30.41 TOTAL 100.00

Each of the four pre-ground whole grains may be prepared by separatelyFitzmilling the raw whole grains using a ⅛ inch round holes screen. Thewater and salt may be pre-mixed and added to a Lauhoff rotary steampressure cooker. The water temperature may be about 170° F.-190° F.Then, all the Fitzmilled multi-whole grains may be incorporated into thepressure cooker at the same time in one step. The four pre-ground wholegrains may be preblended or separately added to the pressure cooker atthe same time. A substantially homogenous or uniform blend of the grainsis preferably used. The mass in the cooker may then be heated with steamand cooked for about 15-30 minutes at a pressure of about 15-26 psig anda temperature of about 268° F. to about 275° F. to fully gelatinize thestarch of the multi-whole grain particles.

The cooked multi-whole grain particles may then be discharged from therotating cooker, and the cooled cooked material is then Comilled using a1 inch square screen to obtain multi-whole grain small grits. The smallgrits may then be conveyed to a grit bin or curing (tempering) tank. Thecooked multi-whole grain small grits may be tempered in the grit bin for1 to 3 hours, with a target tempering time of about 2 hours. The cooked,tempered multi-whole grain particles may have a moisture content ofabout 34.5% by weight for shredding.

The cooked tempered multi-whole grain small grits and natural cheese areblended together in a 90:10 wt %:wt % ratio, respectively. This blendingof the multi-whole grain small grits and cheese may be performed beforethe introduction of these ingredients to a pelletizer, or,alternatively, these ingredients can be separately introduced in a feedzone of a pelletizer and for blending within the pelletizer. The cookedtempered grits and cheese blend may be pelletized in a Bonnet pelletizerhaving a solid or cut flight screw, internal and external knives, and adie plate having 3/16 inch apertures and an open die area of about 38%to about 42%. The tempered agglomerates may be formed into pellets at apressure of about 450 psig to about 700 psig. The pelletizer coolingunit may be set to about 40° F. to cool the jacket of the pelletizer sothe pellets exiting the pelletizer have a pellet temperature of about95° F. to about 105° F. to avoid potential stickiness issues at thedownstream shredder, triangular cutter head, and smooth compressionroll. Air may be introduced at the die cutter to disperse the pellets.The whole grain/cheese composite pellets obtained from the pelletizerare soft, pliable and coherent, and may have a length of about ⅛ inch toabout ¼ inch and a diameter of about 3/16 inch.

The discrete, free flowing multi-whole grain/cheese composite pelletsmay then be conveyed to a surge hopper for feeding to one or moreshredding mills which are arranged in a linear series along a commonconveyor, such as described in Example 1. Natural low moisture cheesemay be added between the shredded layers or on top of the shreddedlayers. The net-like cereal dough sheets produced by the shredding millsmay be continuously deposited upon a continuous conveyor belt to form amulti-layer, e.g., four layer, whole grain laminate having a thicknessof about 0.06-0.10 of an inch. The multi-layer multi-whole grain/cheesecomposite laminate is compressed using a smooth roll, cut into discretepieces of a desired shape and size, and baked and seasoned to produce acheese-containing chip-like snack which can be packaged, such asdescribed in Example 1.

EXAMPLE 4 Multi-Whole Grain and Fruit Shredded Snack

The ingredients and their relative amounts that may be used to produce athin, crisp, chip-like, multi-whole grain and fruit shredded snack are:

Amount Ingredient (Weight %) Pre-ground whole wheat (about 13% by weightwater) 17.35 Pre-ground whole brown rice (about 13% by weight water)17.35 Pre-ground whole oat groats (about 13% by weight water) 17.35Pre-ground whole yellow corn (about 13% by weight water) 17.35 Wholeevaporated apples 15.60 Water 15.00 TOTAL 100.00

Each of the four pre-ground whole grains may be prepared by separatelyFitzmilling the raw whole grains using a ⅛ inch round holes screen. Allthe Fitzmilled multi-whole grains may be incorporated into the pressurecooker at the same time in one step. The evaporated apples may be mixedwith the water and then blended with the pre-ground whole grains in aribbon blender, and then the resulting mixture is introduced at the sametime into a pressure cooker, such as in a Lauhoff rotary steam pressurecooker. A substantially homogenous or uniform blend of the grains andfruit is preferably used. The water temperature may be about 170°F.-190° F. The mass in the cooker may then be heated with steam andcooked for about 15-30 minutes at a pressure of about 15-26 psig and atemperature of about 268° F. to about 275° F. to fully gelatinize thestarch of the multi-whole grain particles.

The cooked multi-whole grain particles/fruit mixture may then bedischarged from the rotating cooker, and the cooled cooked material isthen Comilled using a 1 inch square screen to obtain multi-whole grainsmall grits. The small grits may then be conveyed to a grit bin orcuring (tempering) tank. The cooked multi-whole grain small grits may betempered in the grit bin for 1 to 3 hours, with a target tempering timeof about 2 hours. The cooked, tempered multi-whole grain particles mayhave a moisture content of about 34.5% by weight for shredding.

The cooked tempered multi-whole grain small grits and fruit combinationis pelletized. The cooked tempered grits and fruit blend may bepelletized in a Bonnet pelletizer having a solid or cut flight screw,internal and external knives, and a die plate having 3/16 inch aperturesand an open die area of about 38% to about 42%. The temperedagglomerates may be formed into pellets at a pressure of about 450 psigto about 700 psig. The pelletizer cooling unit may be set to about 40°F. to cool the jacket of the pelletizer so the pellets exiting thepelletizer have a pellet temperature of about 95° F. to about 105° F. toavoid potential stickiness issues at the downstream shredder, triangularcutter head, and smooth compression roll. Air may be introduced at thedie cutter to disperse the pellets. The whole grain/fruit compositepellets obtained from the pelletizer are soft, pliable and coherent, andmay have a length of about ⅛ inch to about ¼ inch and a diameter ofabout 3/16 inch.

The discrete, free flowing multi-whole grain/fruit composite pellets maythen be conveyed to a surge hopper for feeding to one or more shreddingmills which are arranged in a linear series along a common conveyor,such as described in Example 1. Whole fruit powder alone or incombination with sugar/condiments may be added between the shreddedlayers or on top of the shredded layers. Alternatively bakable fruitfilling may be added between the layers to produce product withcrunchy-chewy texture. The net-like cereal dough sheets produced by theshredding mills may be continuously deposited upon a continuous conveyorbelt to form a multi-layer, e.g., four layer, whole grain laminatehaving a thickness of about 0.06-0.10 of an inch. The multi-layermulti-whole grain/fruit composite laminate is compressed using a smoothroll, cut into discrete pieces of a desired shape and size, and bakedand seasoned to produce a fruit-containing chip-like snack which can bepackaged, such as described in Example 1.

EXAMPLE 5 Multi-Whole Grain and Vegetable Shredded Snack

The ingredients and their relative amounts that may be used to produce athin, crisp, chip-like, multi-whole grain and vegetable shredded snackare:

Amount Ingredient (Weight %) Pre-ground whole wheat (about 13% by weightwater) 14.33 Pre-ground whole brown rice (about 13% by weight water)14.33 Pre-ground whole oat groats (about 13% by weight water) 14.33Pre-ground whole yellow corn (about 13% by weight water) 14.33 Driedwhole vegetables 18.75 Frozen whole vegetables 7.30 Water 16.63 TOTAL100.00

Each of the four pre-ground whole grains may be prepared by separatelyFitzmilling the raw whole grains using a ⅛ inch round holes screen.Frozen whole vegetables are thawed prior to use. All the Fitzmilledmulti-whole grains may be incorporated into the pressure cooker at thesame time in one step. The thawed vegetables and dried vegetables may bemixed with the water and then blended with the pre-ground whole grainsin a ribbon blender, and then the resulting mixture is introduced at thesame time into a pressure cooker, such as in a Lauhoff rotary steampressure cooker. A substantially homogenous or uniform blend of thegrains and vegetables is preferably used. The water temperature may beabout 170° F.-190° F. The mass in the cooker may then be heated withsteam and cooked for about 15-30 minutes at a pressure of about 15-26psig and a temperature of about 268° F. to about 275° F. to fullygelatinize the starch of the multi-whole grain particles.

The cooked multi-whole grain particles/vegetables mixture may then bedischarged from the rotating cooker, and the cooled cooked material isthen Comilled using a 1 inch square screen to obtain multi-whole grainsmall grits. The small grits may then be conveyed to a grit bin orcuring (tempering) tank. The cooked multi-whole grain small grits may betempered in the grit bin for 1 to 3 hours, with a target tempering timeof about 2 hours. The cooked, tempered multi-whole grain particles mayhave a moisture content of about 34.5% by weight for shredding.

The cooked tempered multi-whole grain small grits and vegetablescombination is pelletized. The cooked tempered grits and vegetable blendmay be pelletized in a Bonnet pelletizer having a solid or cut flightscrew, internal and external knives, and a die plate having 3/16 inchapertures and an open die area of about 38% to about 42%. The temperedagglomerates may be formed into pellets at a pressure of about 450 psigto about 700 psig. The pelletizer cooling unit may be set to about 40°F. to cool the jacket of the pelletizer so the pellets exiting thepelletizer have a pellet temperature of about 95° F. to about 105° F. toavoid potential stickiness issues at the downstream shredder, triangularcutter head, and smooth compression roll. Air may be introduced at thedie cutter to disperse the pellets. The whole grain/vegetable compositepellets obtained from the pelletizer are soft, pliable and coherent, andmay have a length of about ⅛ inch to about ¼ inch and a diameter ofabout 3/16 inch.

The discrete, free flowing multi-whole grain/vegetable composite pelletsmay then be conveyed to a surge hopper for feeding to one or moreshredding mills which are arranged in a linear series along a commonconveyor, such as described in Example 1. Whole vegetable powder aloneor in combination with herbs/condiments may be added between theshredded layers or on top of the shredded layers. Alternatively bakablevegetable filling may be added between the layers to produce productwith crunchy-chewy texture. The net-like cereal dough sheets produced bythe shredding mills may be continuously deposited upon a continuousconveyor belt to form a multi-layer, e.g., four layer, whole grainlaminate having a thickness of about 0.06-0.10 of an inch. Themulti-layer multi-whole grain/vegetable composite laminate is compressedusing a smooth roll, cut into discrete pieces of a desired shape andsize, and baked and seasoned to produce a vegetable-containing chip-likesnack which can be packaged, such as described in Example 1.

It will be understood that various changes in the details, materials,and arrangements of formulations and ingredients, which have been hereindescribed and illustrated in order to explain the nature of theinvention may be made by those skilled in the art within the principleand scope of the invention as expressed in the appended claims.

What is claimed is:
 1. A method for producing a shredded composite foodproduct, the method comprising: cooking particles of whole cereal grainto provide a cooked whole cereal grain product; tempering the cookedwhole cereal grain product to provide a tempered product, the temperedproduct having retrograded starch; adding a food component selected fromthe group consisting of sweet potatoes, potatoes, cabbage, carrots,spinach, broccoli, peas, peppers, zucchini, okra, Brussels sprouts,cucumber, tomatoes, and any combinations thereof to the particles of thewhole cereal grain or to the cooked whole cereal grain, before or duringa pelletization step; pelletizing the tempered product, the pelletizingto effect shear in an amount and at a temperature effective to providecomposite food pellets having a texture that is softer and more pliablethan prior to pelletization, a moisture content of about 33% to about38% by weight, and a pellet temperature of about 80° F. to about 105°F., the composite food pellets comprising the food component; shreddingthe composite food pellets having a moisture content of about 33% toabout 38% by weight to provide shredded composite food sheets; forming ashredded composite food laminate from the shredded composite foodsheets; and frying the shredded composite food laminate to obtain ashredded composite food product.
 2. The method for producing a shreddedcomposite food product as claimed in claim 1, wherein the whole grainparticles are selected from the group consisting of rye, oats, rice,barley, corn, and triticale.
 3. The method for producing a shreddedcomposite food product as claimed in claim 2, wherein the whole cerealgrain particles comprise a combination of different types of whole grainparticles.
 4. A method for producing a shredded composite food product,the method comprising: a) providing a whole grain-containing mixturecomprising cooked and tempered particles of whole cereal grain and afood component selected from the group consisting of sweet potatoes,potatoes, cabbage, carrots, spinach, broccoli, peas, peppers, zucchini,okra, Brussels sprouts, cucumber, tomatoes, and any combinationsthereof; b) pelletizing the whole grain-containing mixture in apelletizer, the pelletizing to effect shear in an amount and at atemperature effective to provide composite food pellets having a texturethat is softer and more pliable than prior to pelletization, a moisturecontent of about 33% to about 38% by weight, and a pellet temperature ofabout 80° F. to about 105° F.; c) shredding the composite food pelletshaving a moisture content of about 33% to about 38% to provide shreddedcomposite food sheets; d) laminating the shredded composite food sheetsto obtain a shredded composite food laminate; e) dividing the shreddedcomposite food laminate into discrete composite food pieces; and f)frying the shredded composite food laminate prior to step e) orcomposite food pieces after step e) to obtain a shredded composite foodproduct.
 5. The method for producing a shredded composite food productas claimed in claim 4, wherein the whole grain particles are selectedfrom the group consisting of rye, oats, rice, barley, corn, andtriticale.
 6. The method for producing a shredded composite food productas claimed in claim 5, comprising, prior to step a), providing thecooked and tempered whole grain particles by admixing whole cereal grainparticles with water and pressure cooking the whole cereal grainparticles to gelatinize starch of the whole grain particles to providecooked whole grain particles, and tempering the cooked, whole grainparticles to provide the cooked and tempered whole grain particles. 7.The method for producing a shredded composite food product as claimed inclaim 6, wherein the whole grain-containing mixture comprises acombination of whole grain particles and the food component in a mixingratio of about 20:80 to about 95:05, on a wt %:wt % basis, respectively.8. The method for producing a shredded composite food product as claimedin claim 6, wherein the cooking is conducted at a temperature of atleast about 250° F. at a pressure of about 15 psig to about 30 psig, andwherein the tempering is for about 0.5 hour to about 5 hours at atemperature of less than about 135° F.
 9. The method for producing ashredded composite food product as claimed in claim 6, wherein providingthe whole grain-containing mixture comprises combining a first foodcomponent selected from the group consisting of fruit and the foodcomponent with at least one of i) the whole cereal grain particles priorto completion of the cooking thereof, and ii) the cooked and temperedwhole grain particles before completing the pelletizing.
 10. The methodfor producing a shredded composite food product as claimed in claim 9,wherein the moisture content of the cooked whole grain particles is fromabout 29% by weight to about 42% by weight, based upon the weight of thecooked whole grain particles.
 11. The method for producing a shreddedcomposite food product as claimed in claim 5, wherein the food componentis selected from the group consisting of a juice, a puree, a powder andcombinations thereof.
 12. The method for producing a shredded compositefood product as claimed in claim 5, wherein the whole cereal grainparticles comprise a combination of different types of whole grainparticles.
 13. The method for producing a shredded composite foodproduct as claimed in claim 5, wherein the pelletizing effects shear inan amount and at a temperature effective to reduce retrogradation of thestarch of the tempered whole grain particles to increase theirshreddability.
 14. The method for producing a shredded composite foodproduct as claimed in claim 5, wherein the pelletizing is at a pressureof about 200 psig to about 700 psig and the pelletizing temperature iscontrolled to provide a pellet temperature of from about 80° F. to about105° F. upon exiting the pelletizer.
 15. The method for producing ashredded composite food product as claimed in claim 5, wherein thecomposite food pellets have a length of about ⅛ inch to about ¼ inch anda diameter of about 3/16 inch to about 5/16 inch and are produced byextrusion through a pelletizer extrusion die having a plurality ofapertures, wherein the extrusion die has an open area of about 25% toabout 45%.
 16. The method for producing a shredded composite foodproduct as claimed in claim 5, wherein said whole grain particles areobtained by comminuting whole grains or kernels to a particles size ofabout 0.05 inch to about 0.20 inch.
 17. The method for producing ashredded composite food product as claimed in claim 5, wherein theshredded composite food laminate is compressed to a thickness of about0.05 inch to about 0.12 inch and the compressed shredded composite foodlaminate is cut into pieces.
 18. The method for producing a shreddedcomposite food product as claimed in claim 5, wherein whole soy seeds orcomminuted whole soy seeds are admixed with the whole grain particles.19. A method for producing a coated, shredded food product, the methodcomprising: cooking particles of whole cereal grain to provide a cookedwhole cereal grain product; tempering the cooked whole cereal grainproduct to provide a tempered product, the tempered product havingretrograded starch; pelletizing the tempered product, the pelletizing toeffect shear in an amount and at a temperature effective to provide foodpellets having a texture that is softer and more pliable than prior topelletization, a moisture content of about 33% to about 38% by weight,and a pellet temperature of about 80° F. to about 105° F.; shredding thefood pellets having a moisture content of about 33% to about 38% byweight to provide shredded food sheets; forming a shredded food laminatefrom the shredded food sheets; dividing the shredded food laminate intodiscrete shredded food pieces; and frying the discrete shredded foodpieces to obtain fried, shredded food substrates; coating the fried,shredded food substrates with a coating containing cocoa to providecoated, shredded food products.
 20. The method for producing a coatedshredded food product as recited in claim 19, wherein the whole grainparticles are selected from the group consisting of rye, oats, rice,barley, corn, and triticale.
 21. The method for producing a coatedshredded food product as recited in claim 19, wherein the pelletizing isat a pressure of about 200 psig to about 700 psig and the pelletizingtemperature is controlled to provide a pellet temperature of from about80° F. to about 105° F. upon exiting the pelletizer.
 22. A method forproducing a shredded composite food product, the method comprising:cooking particles of whole cereal grain to provide a cooked whole cerealgrain product; tempering the cooked whole cereal grain product toprovide a tempered product, the tempered product having retrogradedstarch; adding a food component selected from the group consisting offruits, dairy cheese and combinations thereof, wherein if the foodcomponent comprises fruits it is added before or during a pelletizationstep, and if the food component comprises dairy cheese, the dairy cheeseis added before or during the pelletization step but after the temperingstep; pelletizing the tempered product, the pelletizing to effect shearin an amount and at a temperature effective to provide composite foodpellets having a texture that is softer and more pliable than prior topelletization, a moisture content of about 33% to about 38% by weight,and a pellet temperature of about 80° F. to about 105° F., the compositefood pellets comprising the food component; and shredding the compositefood pellets having a moisture content of about 33% to about 38% byweight to provide a shredded composite food product; and frying theshredded composite food pellets to obtain a shredded composite foodproduct.
 23. The method for producing a shredded composite food productas claimed in claim 22, wherein the whole grain particles are selectedfrom the group consisting of rye, oats, rice, barley, corn, andtriticale.
 24. The method for producing a shredded composite foodproduct as claimed in claim 23, wherein the food component is selectedfrom the group consisting of raw fruits, frozen fruits, evaporatedfruits, fruit juices, fruit purees, fruit powders, and any combinationthereof.
 25. The method for producing a shredded composite food productas claimed in claim 23, wherein the food component comprises dairycheese having a moisture content of less than about 20 wt %.
 26. Themethod for producing a shredded composite food product as claimed inclaim 23, wherein the whole cereal grain particles comprise acombination of different types of whole grain particles.
 27. The methodfor producing a shredded composite food product as claimed in claim 23,wherein the pelletizing is at a pressure of about 200 psig to about 700psig and the pelletizing temperature is controlled to provide a pellettemperature of from about 80° F. to about 105° F. upon exiting thepelletizer.
 28. A method for producing a shredded composite foodproduct, the method comprising: cooking particles of whole cereal grainto provide a cooked whole cereal grain product; tempering the cookedwhole cereal grain product to provide a tempered product, the temperedproduct having retrograded starch; adding a food component to theparticles of the whole cereal grain or to the cooked whole cereal grain,the food component selected from the group consisting of fruits, anddairy cheese, wherein if the food component comprises fruits, the fruitsare added before or during a pelletization step, and if the foodcomponent comprises dairy cheese, the dairy cheese is added before orduring the pelletization step but after the tempering step; pelletizingthe tempered product, the pelletizing to effect shear in an amount andat a temperature effective to provide composite food pellets having atexture that is softer and more pliable than prior to pelletization, amoisture content of about 33% to about 38% by weight, and a pellettemperature of about 80° F. to about 105° F., the composite food pelletscomprising the food component; shredding the composite food pelletshaving a moisture content of about 33% to about 38% by weight to provideshredded composite food sheets; forming a shredded composite foodlaminate from the shredded composite food sheets; and frying theshredded composite food laminate to obtain a shredded composite foodproduct.
 29. The method for producing a shredded composite food productas claimed in claim 28, wherein the whole grain particles are selectedfrom the group consisting of rye, oats, rice, barley, corn, andtriticale.
 30. The method for producing a shredded composite foodproduct as claimed in claim 29, wherein the food component is selectedfrom the group consisting of raw fruits, frozen fruits, evaporatedfruits, fruit juices, fruit purees, fruit powders, and any combinationthereof.
 31. The method for producing a shredded composite food productas claimed in claim 29, wherein the food component comprises dairycheese having a moisture content of less than about 20 wt %.
 32. Themethod for producing a shredded composite food product as claimed inclaim 29, wherein the whole cereal grain particles comprise acombination of different types of whole grain particles.
 33. A methodfor producing a shredded composite food product, the method comprising:a) providing a whole grain-containing mixture comprising cooked andtempered particles of whole cereal grain and a food component selectedfrom the group consisting of fruit, and dairy cheese; b) pelletizing thewhole grain-containing mixture in a pelletizer, the pelletizing toeffect shear in an amount and at a temperature effective to providecomposite food pellets having a texture that is softer and more pliablethan prior to pelletization, a moisture content of about 33% to about38% by weight, and a pellet temperature of about 80° F. to about 105°F.; c) shredding the composite food pellets having a moisture content ofabout 33% to about 38% to provide shredded composite food sheets; d)laminating the shredded composite food sheets to obtain a shreddedcomposite food laminate; e) dividing the shredded composite foodlaminate into discrete composite food pieces; and f) frying the shreddedcomposite food laminate prior to step e) or composite food pieces afterstep e) to obtain a shredded composite food product.
 34. The method forproducing a shredded composite food product as claimed in claim 33,wherein the whole grain particles are selected from the group consistingof rye, oats, rice, barley, corn, and triticale.
 35. The method forproducing a shredded composite food product as claimed in claim 34,wherein the food component is selected from the group consisting of rawfruits, frozen fruits, evaporated fruits, fruit juices, fruit purees,fruit powders, and any combination thereof.
 36. The method for producinga shredded composite food product as claimed in claim 34, wherein thefood component comprises dairy cheese having a moisture content of lessthan about 20 wt %.
 37. The method for producing a shredded compositefood product as claimed in claim 34, wherein the whole cereal grainparticles comprise a combination of different types of whole grainparticles.
 38. The method for producing a shredded composite foodproduct as claimed in claim 34, wherein the pelletizing is at a pressureof about 200 psig to about 700 psig and the pelletizing temperature iscontrolled to provide a pellet temperature of from about 80° F. to about105° F. upon exiting the pelletizer.
 39. A method for producing ashredded composite food product, the method comprising: cookingparticles of whole cereal grain to provide a cooked whole cereal grainproduct; tempering the cooked whole cereal grain product to provide atempered product, the tempered product having retrograded starch; addinga food component selected from the group consisting of garlic, onion,beans and combinations thereof to the particles of the whole cerealgrain or to the cooked whole cereal grain, before or during apelletization step; pelletizing the tempered product, the pelletizing toeffect shear in an amount and at a temperature effective to providecomposite food pellets having a texture that is softer and more pliablethan prior to pelletization, a moisture content of about 33% to about38% by weight, and a pellet temperature of about 80° F. to about 105°F., the composite food pellets comprising the food component; shreddingthe composite food pellets having a moisture content of about 33% toabout 38% by weight to provide shredded composite food sheets; forming ashredded composite food laminate from the shredded composite foodsheets; and frying the shredded composite food laminate to obtain ashredded composite food product.
 40. The method for producing a shreddedcomposite food product as claimed in claim 39, wherein the whole grainparticles are selected from the group consisting of rye, oats, rice,barley, corn, and triticale.
 41. The method for producing a shreddedcomposite food product as claimed in claim 40, wherein the whole cerealgrain particles comprise a combination of different types of whole grainparticles.
 42. A method for producing a shredded composite food product,the method comprising: a) providing a whole grain-containing mixturecomprising cooked and tempered particles of whole cereal grain and afood component selected from the group consisting of garlic, onion,beans and combinations thereof; b) pelletizing the wholegrain-containing mixture in a pelletizer, the pelletizing to effectshear in an amount and at a temperature effective to provide compositefood pellets having a texture that is softer and more pliable than priorto pelletization, a moisture content of about 33% to about 38% byweight, and a pellet temperature of about 80° F. to about 105° F.; c)shredding the composite food pellets having a moisture content of about33% to about 38% to provide shredded composite food sheets; d)laminating the shredded composite food sheets to obtain a shreddedcomposite food laminate; e) dividing the shredded composite foodlaminate into discrete composite food pieces; and f) frying the shreddedcomposite food laminate prior to step e) or composite food pieces afterstep e) to obtain a shredded composite food product.
 43. The method forproducing a shredded composite food product as claimed in claim 42,wherein the whole grain particles are selected from the group consistingof rye, oats, rice, barley, corn, and triticale.
 44. The method forproducing a shredded composite food product as claimed in claim 43,wherein the whole cereal grain particles comprise a combination ofdifferent types of whole grain particles.